Experimental program and considerations, frequency characteristics, subjective and objective sound quality evaluation and prediction model establishment of a certain mass-production SUV (Sport Utility Vehicle, SUV) manual transmission gear rattle phenomenon were analyzed in this paper. Firstly, vehicle experiment schemes, including experimental operating conditions, vibration acceleration sensor and microphone arrangements and especial considerations in experiments, were introduced in detail. Secondly, through coherence analysis in frequency domain and time-frequency analysis in time-frequency domain, broadband characteristics of manual transmission gear rattle vibro-impact and frequency range of 350~4500Hz were concluded on vehicle idling condition and creeping condition. Thirdly, based on bandwidth filtering processing of gear rattle noise, subjective assessment experiments by paired comparison method, evaluation results of which passed triangle circulation misjudgment and Spearman correlation coefficient examinations, were carried out and subjective annoyance results of each gear rattle noise sample were then calculated. Further, objective evaluation results, based on two physical acoustics parameters and six psychological acoustics parameters, were obtained respectively. Finally, comprehensive evaluation of subjective and objective results was analyzed by the MLR (Multiple Linear Regression, MLR) method. It's concluded that AI (Articulation Index, AI) was the appropriate parameter that's closely related to subjective annoyance results, and correlation coefficient of AI and subjective annoyance results was up to 0.948. Sound quality prediction model of gear rattle was then established on vehicle idling condition and creeping condition. Overall in this paper, research content and method could be adopted to solve practical engineering problems (especially gear rattle problem), and furthermore it could reduce R&D (Research and Design, R&D) cycle, labor costs and material costs dramatically.