Novak Conversions Jeep Wrangler TJ radiator

Need help with a clunking on acceleration from a stop

HammeredSole

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Northern Georgia
I'm having a strange rapid thumping on heavy acceleration from a stop. I just finished extensive suspension and engine service, and the thing is tight as a drum. It's a 2004 X 4.0 automatic. I just replaced ALL of the suspension, control arms, springs, bilstein 5100s, full brakes from Mrblaine, extensive engine service, seals, cam gears etc. It has a Ten Factory SYE and CV shaft, and the inside of the transfer case was tight and all bearings were good when I did the SYE install and partial rebuild kit from JD conversions. It also has a freshly installed Savvy TC cable shift.

This noise was also happening before I did the SYE with the original rear shaft. Essentially, when accelerating from a dead stop with moderate to heavy throttle, the jeep jumps off the line, after just a moment there is a rapid thudding (clearly rotational) that sounds like it's right under the jeep. It generally happens for 3-5 "thuds" and stops. If I release the throttle it goes away, and never presents when rolling, even if I accelerate hard from just 3mph or something slow. I took a hard look at the Trans mount when it was out while I was doing the SYE, all of the rear suspension was torqued to spec on the ground, and has all new control arms, track bar, etc. I'm seriously scratching my head.
 
Have you checked your U-joints lately?

It has a brand new ten factory shaft. With the rear shaft out completely, fwd mode, it did not make the noise. I was absolutely convinced it would stop with the new parts. I was hoping that someone has experience with the particular noise, as it seems very specific and under very specific conditions.

Also, it's got a brand new exhaust and rubber hangers. The muffler and pipe are completely tight and obstruction free.
 
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Does it do it in four-wheel-drive?

Your comment about the rear shaft led me to question the transfer case.

I'll go try it out. I had worried the same, but everything went back together and appeared damage free when I split the case out of the truck for the SYE and all external seal replacements. I had initially thought that maybe the rear output bearing was bad, but now it's got the new SYE kit.
 
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Ok, I stuck a GoPro on the skid plate, positioned so it can the whole back of the transfer case, the drive shaft, and the rear differential. I was able to replicate it, and it the noise manifests under high torque (ie lots of throttle from dead stop) and it is the transfer case shaking. I had the transmission mount IN MY HAND, turning it, pulling on rubber, bolts, pushing, twisting... and it seemed fine.

Here's a youtube video. Most of the action is at 5:00 and forward, but it does it intermittently throughout. It seems obvious, but I'm also hearing the hollowness of the transfer case, so it's hard to say 100% it's the t-case hitting something externally. Again, everything went back together well, all bearing rolled smooth, no chunks in case, filter, fluid, etc, and all ranges work and select as prescribed.


What do you think, will the transmission mount remedy this?
 
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Just a thought after watching video: doublecheck check the driveshaft length? The rear pinion is rotating upwards under acceleration. If the shaft is to long....
 
Mine occasionally does something similar on rough roads.
I assume it's the transfer case hitting the bottom of the tub.
Guess I didn't clearance it enough after doing a tummy tuck, plus the aluminum skid may be flexing.
 
How about the motor mounts? Is the rubber in good condition?

Not sure. They appear okay, but they are 20 years old. I am getting repair fatigue on this, as I've done nearly an entire restoration in the last 6 weeks. Full brakes, full suspension, entire engine seal package with oil pump, cam gear, water pump, T case rebuild with SYE, etc. Now last night I found coolant on the passenger floor when I pulled the carpet. The Jeep is looking and driving great, and I can see the light at the end of the tunnel, but my god. The PO was so proud of his annual Wal-Mart oil change invoices, but he neglected literally everything else. I'm also discovering a hard start stumble when it's cold out, probably dead/weak battery not really charging the fuel and ignition system without sufficient RPM to drive the alternator, but possibly IAC. I am concerned with completing all loose ends, as I feel that crunch to obtain quickly dwindling OEM supply.

Anyways, I found a NOS OEM transmission mount on Ebay that should be here today or tomorrow, and some MORE bombproof JM600 rubber mounts by Wednesday. Watching the video it's clear that the mount is just overwhelmed with torque and displaces itself. I'm hopeful that tightening up the drivetrain mount tripod will remedy this.
 
Quick update on this; replaced the OEM motor mounts with MORE bomb proof rubber mounts and the vibration is essentially eliminated and doesn't clank anymore. Going to install the OEM trans mount and report back.
 
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Quick update on this; replaced the OEM motor mounts with MORE bomb proof rubber mounts and the vibration is hardly present, and doesn't clank anymore. Going to install the OEM trans mount and report back.

Care to share what mounts you decided on, perhaps a link even?
 
Just wanting to circle back and close this up. I found a new old stock OEM transmission mount on eBay. Got it installed, and all clunking, talking, shaking is gone. The original mount wasn't separated, but maybe a bit soft on one corner when putting body weight into the assembly. Visually checking it and holding it once it was out wouldn't suggest it was bad, but the new trans mount and MORE mounts tightened everything up.
 
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Novak Conversions Jeep Wrangler TJ radiator