I looked into the Rubicon's very annoying rattle today. It was a rattle coming from near the engine at certain rpms. To fix it, for me at least, take that black cover off that covers the exhaust header. Then if you look you should see the metal exhaust shield touching one of the metal bolts that holds the electrical connector onto the engine case right below the pipe. That's the problem. Loosen the hose clamps on the heat shield and move it ahead slightly, then tighten it back up and put the black cover back on. The rattle should be gone. On our Rubicon, the heat shield wore into the bolt quite a bit, took the corner pretty much off. Now the Rubicon sounds even better when riding it. This only applies to people with a rattling Rubicon.

 

That's crazy I had that problem too! I'm glad im not the only one...thanks for the tip, i was tryin to figure out where it came from...only at certain rpms does mine rattle....well thanks a lot! later

01 Rubicon
00 Foreman S
00 Rancher TE
98 Recon

 

MOVED MY HEAT SHIELD ABOUT 1/8" RATTLE IS GONE."THANK YOU"

 

I am new to this forum and I know you posted this a long time ago. But you have made my day on the solution to the rattle on Rubicon. It was exactly what you said. I have been riding this thing for two years with that annoying rattle. I HATE noises that aren't supposed to be there. God bless you my son!!!! Thanks