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PB -PC Challenger 2009 - 2014 Covering 2.5 HP diesel

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Old 16-02-20
westvic westvic is offline
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Default Rocks in chassis rail

My PC has developed a rattle. It is a metalic sounding thing that sounds like loose washers being rattled somewhere and only at certain frequencies. I have checked everything I can think of. It has been up on a hoist for suspension check (and every thing else) and been through the local dealer for a service. Still nothing has been found. At least that rules out anything obvious.

I'm now strongly suspecting I've picked up a stone (or several) in the chassis rail. Anyone got some tips or advice on how to remove stones from in there?

thanks in advance
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Old 16-02-20
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old Jack old Jack is online now
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Remove the end fitting off a garden hose and insert the hose into the access holes in the high points of the chassis in the wheel arches. Run the hose at full pressure and you will see a stream of sand, dirt, grit and rocks flow from the chassis drain holes.

I do this every time I clean the car after an off bitumen trip and are surprised at what collects inside the chassis rails.

I doubt this is your problem.

I would be also looking at the bash plate mounts, there are 6 in total, these crack even when the factory splash plates are fitted. When these mounts break you get a metallic rattle you can hear from the cabin.

OJ.
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Old 16-02-20
Kingbrown Kingbrown is online now
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I recall a few instances of a loose shroud surrounding the rear output shaft & seal of the transfer case. Might be worth a look to see if that shroud has come adrift..

Attached to the chassis rails just behind the front wheels there are two 'boxes' that I think are support points. These 'boxes' can easily catch a handful of gravel or rocks. You have to bend your wrist in a tight arc and reach into the top of the boxes to feel for debris.

The rear mudflaps are formed with a large void in the moulded upper part, just behind and directly above the mudflaps. . There's only a small drain hole for that void but plenty of rocks get trapped in there. Again, you need to have 'Inspector Gadget' hands to feel in that space.
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Last edited by Kingbrown; 16-02-20 at 08:31 AM.
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Old 22-02-20
westvic westvic is offline
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Quote:
Originally Posted by old Jack View Post
Remove the end fitting off a garden hose and insert the hose into the access holes in the high points of the chassis in the wheel arches. Run the hose at full pressure and you will see a stream of sand, dirt, grit and rocks flow from the chassis drain holes.

I do this every time I clean the car after an off bitumen trip and are surprised at what collects inside the chassis rails.

I doubt this is your problem.

I would be also looking at the bash plate mounts, there are 6 in total, these crack even when the factory splash plates are fitted. When these mounts break you get a metallic rattle you can hear from the cabin.

OJ.
Thanks OJ. I have double checked all the mounts and all seem fine so not this. The stones I have already pulled out have often been larger than the drain holes in the chassis rails so I dont think a hose will fix this problem.
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Old 22-02-20
westvic westvic is offline
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Quote:
Originally Posted by Kingbrown View Post
I recall a few instances of a loose shroud surrounding the rear output shaft & seal of the transfer case. Might be worth a look to see if that shroud has come adrift..

Attached to the chassis rails just behind the front wheels there are two 'boxes' that I think are support points. These 'boxes' can easily catch a handful of gravel or rocks. You have to bend your wrist in a tight arc and reach into the top of the boxes to feel for debris.

The rear mudflaps are formed with a large void in the moulded upper part, just behind and directly above the mudflaps. . There's only a small drain hole for that void but plenty of rocks get trapped in there. Again, you need to have 'Inspector Gadget' hands to feel in that space.
Thanks Kingbrown. Checked all these and problem still there. I had already cleaned out the boxes and there are 2 towards the rear as well. All had stones in them which were removed but problem still there.

I hadn't checked rear mudflaps though. The drivers side was empty but removed 30+ stones from the passenger side.

The hunt continues.
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