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Discussion Starter #1
Hello All,

I have a 1996 Cherokee (XJ) 4.0L Manual transmission NP231, Chrysler 8.25 rear.

I put a budget boost on it about 75,000 miles ago, and also have an xfer case drop.

Recently it has started giving me a clunking when I let off the gas pedal. It actually seems to be worst when coasting in neutral or with the clutch in, but I get some clunking with engine braking.. Nothing with acceleration or steady state load. I don't really feel anything, just hear a metallic clunking that seems to come from the rear end.

This is not something that has gotten progressively worse... It was fine one day and clunking the next.

After some searches here I checked my u-joints and differential inputs thinking it could be a pinion bearing or u-joints. Neither driveshaft has vertical or horizontal play (Front I can wiggle a tiny bit, maybe 1/2 mm or so). All U-joints also seem fine. Fluid levels are full.

It has been suggested that I check the passenger side engine mount for broken bolts (on my list) and put grease on the x-fer case output shaft. Are these valid points for this type of problem?

What's the next place to look?

Thanks!
 

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Bad U-joints usually whine/vibrate on decel. Clunk on decel could be crush sleeve. Did you remove your drivelines when checking play or try to rotate? How is the clutch?
 

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Discussion Starter #5
I just tried to rotate the shafts with the transmission in neutral.

Clutch works fine, clunking seems to be present regardless of clutch position, or transmission in neutral.

What is the crush sleeve and how do I check?
 
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