I appreciate the out-of-the-box idea..! I unfortunately have the super donut spare, but also have another full size spare on top. I would be taking this suggestion and acting on it, but the dealer has finally finished with it after 6 hours of looking.
The results are: Nothing. Zip, Zilch, Nada.
Yes, after 6 hours, they found nothing. They said they took it out for a drive over and over and couldn't reproduce the noise. I said, "ok, oh well." So got in the Jeep, and it "scratched" right away. Not even 10mph out of the garage. I promptly pulled a U-ey and walked right back in with a new attitude. They sent out the shop foreman who went on a ride with me around the dealership lot (a couple of laps) and said, "Oh, there's definately something wrong". I was like, "Yea, apparently YOUR mechanics did this already, and heard nothing.... So how do you think that could have happened..?!"
He didn't have an answer, other than "let me take it in personally and pull it apart." So he did, and another 2 hours later he came back.
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Still same noise. Then an epiphany dawned on them, and they pulled the calipers off. Right rear pads had a small rock that was somehow lodged in a space just below, and would rattle around, then get stuck (which is the cause of the noise), and then get unstuck... but never fall out (which is why it was intermittent).
So, the Jeep is back to normal
