Help! 1995 YJ - Clanking sound

[kevin77]

Can someone help me? I have a problem with my 1995 YJ (4 banger with 5 spd)that no one seems to be able to fix (permanently).

Here is my sad history:

1994.nov - new purchase
1995.may - smell foul order along with clanking sound at low rev. dealership "tightens" the exhaust manifold bolt. problems goes away
1995.jul - same problem comes back. dealership replaces the catcon. problem solved? I think not.
1995.dec - factory recall for catcon. problem comes back. another catcon replacement.
1996.mar - problem comes back. during the "tightening" process, mechanic breaks the exhaust manifold stud. re-taps the stud and replaces the manifold, catcon and muffler
1996.nov. - problem comes back. at this point, i'm fed up and sue chrysler
1997.may - suit continues. another replacement (exh. mani, catcon, muffler)
1997.dec - problem continues
1998.feb - suit judgement for me. ($2000, big *!^@ing deal!!). problem continues
1998.nov -final catcon replacement under emission warranty. after this, i am on my own
1999.may - REAL FOUL SMELL at 3500 rpm. clanking sound getting louder
2000.jun - another mechanic looks at it, says exhaust pipe bolts loose. tightens them and the problem goes away
2000.oct - oh goodness, the problem is slowly coming back (clanking sound)
2001.jun - a different mechanic looks at it, says the bolt under driver floor pan is broken. replaces it and the problem goes away.
2001.oct - same *&&!ing s*&t prolem again! what the *&&*$#@!!!

I feel like crunching up my jeep but i need to drive this for another year. any suggestions!???!


faulty cat con (replaced under warrantly

[karstman]

Check all the fasteners on the exhaust, especially around the cat conv and the cat heat shield (if it has one).
How does it run? Any other details? Were they all mopar catylitic converters?

Somerset as in PA??

HTH
mark



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Pittsburgh Area Jeepers Click Me (http://groups.yahoo.com/group/PghOffRoad)

[Square Peg]

The smell could be the exhaust heating up the under coating near the the heat shield. Clanking sounds like an engine thing and not an exhaust problem.

[kevin77]

thanks for the input. here are some more info.

jeep seems to run okay. under heavy acceleration, i can definately smell the "rotten eggs" and sense a "blow back" holding back my engine. but according to the last mechanic, muffler is in good condition.
cat.cons - yes, they were all mopar, as far as i was told. one thing i forgot to mention was that the very first time the cat con was replaced, the mechanic told me that chrysler was experiencing lots of problems due to inferior workmanship on this part. once he removed the old cat con, he shooked it and poured out a bunch of white powder as a proof. but since it was replaced so many times, i just can't fathom it being the only problem.
as far as checking fastners - last 2 mechanics did just that. if these were the culprits, how come they don't stay tightened for a longer period of time? do i need to use locktite on these suckers?!

i don't think the clanking sound is coming from the engine, although i am suspecting exh.manifold (since the stud was broken during earlier repair).

as much as i loath jeep (for their inability to fix this problem), i love the truck itself. as a die hard fan, i am thinking about picking up a new kj or tj? do any of you have tj with 90k+ miles? if so, any problems?

ps. somerset = somerset, nj http://forums.jeepsunlimited.com/ubb/smile.gif

[Jeeper]

Where is the clanking sound commig from? Is it up front in the engine compartment or do you hear it more toward the middle of the Jeep? Does it occur all the time or just when turning or accelerating?

Use some lock-tight on the exhaust fasteners.

Jeeper

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99WJ: loaded
90YJ:SB 400, D60/D44, 4.88's, full Detroits, TH350, Atlas II 4.3:1, 38.5x14.50 SX's, 2.5" Alcan Spring SOA, Revolver shackles and Much Much More!
1950 CJ3-A small project
1975 J-10 Parts vehicle

[SB95YJ]

I've got a bad CC myself. It was making a "nice" rattling noise while running. Passed emmisions two years ago fine, this time it barely failed. I've got a used one off a newer TJ that I will put on with a better muffler and larger exhaust...so I'm anxious to see what happens with yours.

BTT

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95YJ,Sahara,5"RE-XD,A.A.SYE,TomWoods CVDS,33BFGMT's,5spd

[JTucker]

put a header, replace cat with pipe or aftermarket cat, and get a catback exhaust. Take it to the muffler shop of choice and have them weld it together