1500 CLUNKING NOISE UPDATE

[TSkeen]

I HAVE SEEN A FEW ARTICLES ABOUT THE CLUNKING NOISE WHEN SHIFTED INTO GEAR AND WHEN YOU GIVE IT GAS AND LET OFF THE GAS. ONE OF THE MAIN REASONS I PURCHASED MY 1500 WAS BECAUSE OF THE SMOOTHNESS AND QUIETNEES OF THE SHIFTING.
MOST ALL OTHER UTV'S IVE DRIVEN WASN'T NEARLY AS NICE AND SMOOTH AS THE 1500 ULTRA XD. WHEN MINE HIT AROUND 1,000 MILES IT STARTED TO CLICK WHEN I SHIFTED IT INTO REVERSE. NOW I'M AT 1400 MILES AND I HAVE THE CLUNKING NOISE I READ ABOUT.
I HAVE EXTENDED WARRANTY, AND I WOULD RATHER SEE A FIX FOR IT THAN BEING AN EXPERIMENT BEFORE TAKING IT TO THE SHOP.
HAS ANYONE HEARD OF A SURE FIX FOR THIS ISSUE YET?

 

[JHammer]

My dealer fixed mine.

 

[rspjr]

My dealer fixed mine.

So, JHammer, what did they do to fix it???

 

[JHammer]

removed the rear wheels and reattached the hub nut

 

[rspjr]

removed the rear wheels and reattached the hub nut

Thanks, I have 3800 miles on mine, and good, so far. No noise!

 

[JHammer]

Mine started at 4300 miles

 

[bierscon]

I HAVE SEEN A FEW ARTICLES ABOUT THE CLUNKING NOISE WHEN SHIFTED INTO GEAR AND WHEN YOU GIVE IT GAS AND LET OFF THE GAS. ONE OF THE MAIN REASONS I PURCHASED MY 1500 WAS BECAUSE OF THE SMOOTHNESS AND QUIETNEES OF THE SHIFTING.
MOST ALL OTHER UTV'S IVE DRIVEN WASN'T NEARLY AS NICE AND SMOOTH AS THE 1500 ULTRA XD. WHEN MINE HIT AROUND 1,000 MILES IT STARTED TO CLICK WHEN I SHIFTED IT INTO REVERSE. NOW I'M AT 1400 MILES AND I HAVE THE CLUNKING NOISE I READ ABOUT.
I HAVE EXTENDED WARRANTY, AND I WOULD RATHER SEE A FIX FOR IT THAN BEING AN EXPERIMENT BEFORE TAKING IT TO THE SHOP.
HAS ANYONE HEARD OF A SURE FIX FOR THIS ISSUE YET?

Dealer fixed might 2024 crew as well. It started at only 20 hours. Now at 75 so far so good. It’s the Locktite fix you’ll read about. Seems like a bandaid but seems to be holding up. Imagine they’ll come up with a better fix but suggest you get it in and documented. Good luck!

 

[Big Red]

removed the rear wheels and reattached the hub nut

Seems like this problem was different from those that have the dreaded "axle clunk" which has to do with slop in the axle splines and the rear differential. I'm not saying it maybe didn't sound or behave the same way, just different from the more problematic issue that Polaris hasn't fully fixed yet.

 

[Clubin]

Dealer fixed mine too. No more clunk. Axles locktite into the diff and the outer. No movement. 3000 km or maybe more on the fix.

 

[Mr.C]

Dealer fixed mine too. No more clunk. Axles locktite into the diff and the outer. No movement. 3000 km or maybe more on the fix.

Lucky!! I’ve got new axles and loctite (supposedly) and mine is back to the way it was. It was improved at first. But only lasted maybe 100 miles or a little more.

 

[Woods Ranger]

Lucky!! I’ve got new axles and loctite (supposedly) and mine is back to the way it was. It was improved at first. But only lasted maybe 100 miles or a little more.

Same here. 100 miles after the loctite fix and the clunk is back worse than before.

 

[Rockotoby]

Same here. 100 miles after the loctite fix and the clunk is back worse than before.

Same here

 

[Clubin]

Lucky!! I’ve got new axles and loctite (supposedly) and mine is back to the way it was. It was improved at first. But only lasted maybe 100 miles or a little more.

Can you check the inner plunge joints into the diff are they solid? Mine are I don’t recall the locktite needing to be installed there but mine was.

 

[Mr.C]

Can you check the inner plunge joints into the diff are they solid? Mine are I don’t recall the locktite needing to be installed there but mine was.

I’ll have to check them once I get back from my elk hunt. The ranger is loaded and strapped in the enclosed trailer right now.

 

[jamcroberts]

I had my ranger at the dealer yesterday for a service. They offered new rear axles under warranty. The Polaris rep said the clunk (atleast in mine) is because there is to much play in the axles. The new ones come with tighter tolerances. The axle nut comes with loctite from the factory now in the 25’s.

 

[Rockotoby]

Dealer tightened the hub nuts, and it didn't work. Went back, dealer did the loctite, lasted very shortly. Goes back in this Monday. My thoughts are the Hubs in the third member were made too big, and everything so far is a band-aid. If you wait too long to fix it, the play wares the hub even bigger, then the new bigger axles don't even fit. I think the real problem is the third member where the axles go in is too big and too expensive for Polaris to accept yet.

 

[JTBarlow]

I had my ranger at the dealer yesterday for a service. They offered new rear axles under warranty. The Polaris rep said the clunk (atleast in mine) is because there is to much play in the axles. The new ones come with tighter tolerances. The axle nut comes with loctite from the factory now in the 25’s.

On the ‘25 XD 1500 I just changed the suspension on, only 1 of the rear axles had loctite on it. Brand new machine from the dealer, so I’m assuming it was done at the factory. Seems odd that they only did one of them, but also annoying to have to use a jaw puller to get the axle out of the hub. And it’ll be more aggravating for anyone who might need to change an axle out on the trail.

 

[LowlyOilBurner]

I had the Loctite fix done a few weeks ago. It SEEMS to be ok, but the more annoying clunk is now from the rear swaybar. Over sharp bumps, there is a distinct “clunk”. I pulled the rear sway, the noise is gone. This is not the fix, as I want the rear sway to remain connected. Machine has around 400miles on it. It only started recently. The bushings/links seem ok. Anyone else with this issue?? I see Shock Therapy sells swaybar links for the 1500. Maybe a fix?

 

[Franklst]

Well back at the dealer again, now been a month and the first time for four months. Dealer did the Loctite, replaced the rear diff and said it was fixed. Had the unit back for two months and the clunk came back worse then it was before. Dealer just replaced the axles and still is making the noise waiting on Polaris to respond on what to do next. Unit is only used around the ranch and has only about half the hours on it until the first service is due. Definitely regretting my purchase.

 

[Clubin]

Well back at the dealer again, now been a month and the first time for four months. Dealer did the Loctite, replaced the rear diff and said it was fixed. Had the unit back for two months and the clunk came back worse then it was before. Dealer just replaced the axles and still is making the noise waiting on Polaris to respond on what to do next. Unit is only used around the ranch and has only about half the hours on it until the first service is due. Definitely regretting my purchase.

Turn up the music. It’s nothing that’ll ever cause you to have to walk. I went through 3 sets of axles and now the rears are locktite inner and outer. F’ the guy that’s going to try get it apart! lol.


3500*km on the last fix. It’s perfect.

Front end is wearing out now. lol. Ball joints and shock bushings.