The only reasonable (possibly logical) thing I can come up with, being it is happening in all of them (or should I say 2 of 2 that I have driven) and have eliminated most of the common issues, are surface-caused vibrations coming up thru the tires and suspension into the walls/floor of the vehicle causing resonant frequencies (which I measured with an ETA) in the 30-40Hz frequency range. The top is trapping and exaggerating those frequencies, which are rather annoying. A soft top will probably help some, but we like the hard top for now.
Using dampening material should tame some of the vibrations in the walls/floor, but if we can also dampen them thru part of what they are traveling thru, that might also help.
We are swapping the wheels/tires out from 275/55/20 to 285/70/17, which may help some. We are not doing this because of the noise, we are doing it because we like the look of the 17" wheels and a little larger tire. The 20" wheels just don't look right on there to us (simply our opinion).
I guess we just attack it from several angles and see how much each one might help if any.
Mmmmm 20" Wheels with a 55 low profile tire.
That my friend would have been good Intel to
share on the first post .
That could possibly be much of the problem .
A low profile tire offers very little forgiveness
or flex. If I'm not mistaken usually low profile
tires run higher pressure as well. Which won't help
your situation .
Most of us run a 17" with the odd 18" out there .
Gives plenty of sidewall for flex & airing down .
That extra sidewall wil also help absorb road noise
and bumps .
On the street like you mentioned it's fine . Going off
road not so much .
Def before you do anything else take care of the tires & wheels .
I'm 90 percent certain it will cut down on noises .
Cause I'm guessing the other Jeep you test drove to
compare had the same tires. For a test and comparison
maybe go to dealer and ask to take a 4 Door JLU with 16 or 17"
wheels for a spin .
Had E rated tires , Rubicon Suspension on a Sahara.
Switched the C load tires and made a ton of difference .
Turns out the E loaded tires are not a good match with
the stiffer Rubicon suspension .
But in
@Danarch sitituation he is able to run a E loaded
tire with an AEV lift and suspension . As the Bilsteins are
tuned to the springs and offer a more forgiving ride .
So tires , wheel size, suspension can all effect the ride
quality and noise .
Keep us in the loop. As this thread will help,others .