Clunk discussion

[oneal]

I got new axles and the dealer applied loctite to them. Let it sit for a couple days to let the loctite cure. My machine still clunks. Not as bad as it was, but it’s still doing it.

That is so disappointing, I hoped they had figured it out with a solid cure.

0ne detail that still doesn't make sense on JUST an axle replacement. The excessive tolerance of the splines is either the axle diameter is too small , the hub bore is too big, the splines are not equally cut, or a combination of both.
For folks like yourself that have lived with the clunk for numerous months and the clunk noise emits from the male and female spline banging back and forth I feel it would wear on the outer spline as well which is the drive hub. I anticipated the "clunk cure" would be new axles and hubs.
Loctite is meant to fill gaps of SLIGHT tolerance issues, I think the reason it worked for me and a small handful of others is because it was applied early before the splines had time to wear on each other.

 

[Mr.C]

I agree, I don’t think just axles is the fix. And I think the loctite thing is a joke. I was told that the axles that were installed are the new part number axles. But he wasn’t quite sure why the part number changed.

I figured, I’m just gonna keep driving it and bring it up whenever it’s in there. That way down the road if there’s ever in issue, I have some sort of documentation.

 

[oneal]

I agree, I don’t think just axles is the fix. And I think the loctite thing is a joke. I was told that the axles that were installed are the new part number axles. But he wasn’t quite sure why the part number changed.

I figured, I’m just gonna keep driving it and bring it up whenever it’s in there. That way down the road if there’s ever in issue, I have some sort of documentation.

I agree, keep a log

 

[Big Red]

I still can't believe a year later this is still going on. Polaris should be better than that!

 

[G1eagle]

I’ve been waiting a while to post to give my local dealer time to work through some things with Polaris. I took my Ranger in on March 12 with a list of things for them to address. It is a year old with @1400 miles. The list included the following:

Transmission update​

Door latch recall​

Clicking noise when backing and you let off gas. Noise was from the transmission area and not a clunk.​

Popping noise from rear. This is rotational popping when turning at @10mph. No clunk when you are on and off gas.​

​

I stopped by the dealer today and met with the tech. I think the first three items have been addressed. The interesting one that I haven’t seen anyone post about was the clicking noise. The tech said the neutral engagement lever was out of adjustment. He adjusted that and clicking is gone.

With regards to the popping, they recorded the popping sound and sent it to Polaris. They had the dealer remove and tear down the rear differential. The tech said everything inside the differential looked good. No metal other than normal amount on drain plug. He also said the lash was good. He said they sent many pictures to Polaris to review. Polaris told them they didn’t see any issues and it was normal operation of the differential. I told my dealer it was not normal as it just started making the noise. I explained I was not satisfied with that response. Dealer pushed back with Polaris and is waiting on a reply.

I asked about the loctite fix and was told my model didn’t fall within the parameters. I’m not sure that’s right but I didn’t push back on that yet.

Dealer has been good to work with and has indicated they have the issue well documented in the event it get worse or fails. If Polaris maintains their position that it’s normal, I’m not sure of my next step. I’m thinking I’ll have to pick it up and drive it to see if it’s gets any worse. My unit has the promotional three year power train warranty. Between that and my dealer’s promise to help me with Polaris if needed down the road, I think I’m covered for a couple more years anyway.

Any thoughts or advice?

​

 

[oneal]

I’ve been waiting a while to post to give my local dealer time to work through some things with Polaris. I took my Ranger in on March 12 with a list of things for them to address. It is a year old with @1400 miles. The list included the following:

Transmission update​

Door latch recall​

Clicking noise when backing and you let off gas. Noise was from the transmission area and not a clunk.​

Popping noise from rear. This is rotational popping when turning at @10mph. No clunk when you are on and off gas.​

​

I stopped by the dealer today and met with the tech. I think the first three items have been addressed. The interesting one that I haven’t seen anyone post about was the clicking noise. The tech said the neutral engagement lever was out of adjustment. He adjusted that and clicking is gone.

With regards to the popping, they recorded the popping sound and sent it to Polaris. They had the dealer remove and tear down the rear differential. The tech said everything inside the differential looked good. No metal other than normal amount on drain plug. He also said the lash was good. He said they sent many pictures to Polaris to review. Polaris told them they didn’t see any issues and it was normal operation of the differential. I told my dealer it was not normal as it just started making the noise. I explained I was not satisfied with that response. Dealer pushed back with Polaris and is waiting on a reply.

I asked about the loctite fix and was told my model didn’t fall within the parameters. I’m not sure that’s right but I didn’t push back on that yet.

Dealer has been good to work with and has indicated they have the issue well documented in the event it get worse or fails. If Polaris maintains their position that it’s normal, I’m not sure of my next step. I’m thinking I’ll have to pick it up and drive it to see if it’s gets any worse. My unit has the promotional three year power train warranty. Between that and my dealer’s promise to help me with Polaris if needed down the road, I think I’m covered for a couple more years anyway.

Any thoughts or advice?

​

Definitely no advice, you documented your issues well and it sounds like you have a good dealer.
Would you describe your machines use as mild off road, hard off road, or street? There seems to be more clunkers and poppers being reported lately.
Ours is definitely mild off road, no street. So far, Loctite cured my clunk but the popping noise is also annoying. Our land is full of off cambers and small ravines and my popping is clearly the suspension linkages, crews are long and I watch the tires constantly using the full amount wheel travel in the mirror.
I have been curious if the high percentage of owners that report no issues or noises take their machines off road.
Either way, Polaris produces off-road vehicles, not golf carts and at 50k they owe us a reliable noise free machine.

 

[G1eagle]

Definitely no advice, you documented your issues well and it sounds like you have a good dealer.
Would you describe your machines use as mild off road, hard off road, or street? There seems to be more clunkers and poppers being reported lately.
Ours is definitely mild off road, no street. So far, Loctite cured my clunk but the popping noise is also annoying. Our land is full of off cambers and small ravines and my popping is clearly the suspension linkages, crews are long and I watch the tires constantly using the full amount wheel travel in the mirror.
I have been curious if the high percentage of owners that report no issues or noises take their machines off road.
Either way, Polaris produces off-road vehicles, not golf carts and at 50k they owe us a reliable noise free machine.

I would say mine is mild off road use. Used for hunting and working in the yard.

 

[Johnnie]

Thank you for the good information.

 

[bierscon]

2024 1500 XD Premium Silver Turbo
Only 30 hours 450 miles
Puchased 3/25
I didn’t notice a rear end clunking the first 20 hours but now it’s very noticeable at accel and deceleration. Engine off and in park if I rock the back wheels back and forth I can hear substantial clunking at the rear differential and also behing wheels. Fluid and axle bolts checked and good. I too am a long way from dealer but asked service to go out and rock a new 1500 back and forth and he stated it clunked too. Worrisome…. Any input greatly appreciated

 

[Big Red]

Yell loudly!! It does not appear Polaris knows how to fix this problem since it keeps happening!

 

[nh 1500 owner]

2024 1500 XD Premium Silver Turbo
Only 30 hours 450 miles
Puchased 3/25
I didn’t notice a rear end clunking the first 20 hours but now it’s very noticeable at accel and deceleration. Engine off and in park if I rock the back wheels back and forth I can hear substantial clunking at the rear differential and also behing wheels. Fluid and axle bolts checked and good. I too am a long way from dealer but asked service to go out and rock a new 1500 back and forth and he stated it clunked too. Worrisome…. Any input greatly appreciated

Thats when mine started we need to gang up on polaris this is getting out of control

 

[JTBarlow]

So I’m in the middle of swapping out the suspension on our XD and came across an issue on the rear. The bolts on the sway bar saddles were loose. I only saw it once the shocks were undone, since the shocks held the suspension in place.
This could potentially cause a clunk noise, though Brian hadn’t reported any to me.

The nylock nuts on these bolts really don’t hold very well. And the saddles being mounted vertically kinda makes it a problem waiting to happen.

My solution for now is red loctite and torque them back up.

Just something y’all might want to check…

 

[oneal]

Might be the source of the pop out of the suspension . The clunk is in rotation rhythm, once per tire rotation. At least mine was.

 

[JTBarlow]

Yeah, reading the posts, most seem like rotational noises. Just figured a few might be something like this.

 

[Mr.C]

So I’m in the middle of swapping out the suspension on our XD and came across an issue on the rear. The bolts on the sway bar saddles were loose. I only saw it once the shocks were undone, since the shocks held the suspension in place.
This could potentially cause a clunk noise, though Brian hadn’t reported any to me.

The nylock nuts on these bolts really don’t hold very well. And the saddles being mounted vertically kinda makes it a problem waiting to happen.

My solution for now is red loctite and torque them back up.

Just something y’all might want to check…

I’ll be checking mine out this weekend if I get back from my dealer again.

 

[G1eagle]

I’ve been waiting a while to post to give my local dealer time to work through some things with Polaris. I took my Ranger in on March 12 with a list of things for them to address. It is a year old with @1400 miles. The list included the following:

Transmission update​

Door latch recall​

Clicking noise when backing and you let off gas. Noise was from the transmission area and not a clunk.​

Popping noise from rear. This is rotational popping when turning at @10mph. No clunk when you are on and off gas.​

​

I stopped by the dealer today and met with the tech. I think the first three items have been addressed. The interesting one that I haven’t seen anyone post about was the clicking noise. The tech said the neutral engagement lever was out of adjustment. He adjusted that and clicking is gone.

With regards to the popping, they recorded the popping sound and sent it to Polaris. They had the dealer remove and tear down the rear differential. The tech said everything inside the differential looked good. No metal other than normal amount on drain plug. He also said the lash was good. He said they sent many pictures to Polaris to review. Polaris told them they didn’t see any issues and it was normal operation of the differential. I told my dealer it was not normal as it just started making the noise. I explained I was not satisfied with that response. Dealer pushed back with Polaris and is waiting on a reply.

I asked about the loctite fix and was told my model didn’t fall within the parameters. I’m not sure that’s right but I didn’t push back on that yet.

Dealer has been good to work with and has indicated they have the issue well documented in the event it get worse or fails. If Polaris maintains their position that it’s normal, I’m not sure of my next step. I’m thinking I’ll have to pick it up and drive it to see if it’s gets any worse. My unit has the promotional three year power train warranty. Between that and my dealer’s promise to help me with Polaris if needed down the road, I think I’m covered for a couple more years anyway.

Any thoughts or advice?

​

Update: I called Polaris yesterday to discuss their position that there is nothing wrong with my Ranger. They say even though there is rotational popping present when turning left or right at @15mph, my ranger is operating normally. I asked them to reevaluate their position and they agreed but I’m not optimistic they will do anything else. They say it is documented if it gets worse.

I’m not sure I have any recourse at the moment. It’s frustrating that this issue persists and their response to cases of other owners has been all over the board. I bet a class attorney would have a lot of fun with their internal communications on this topic.

 

[Clubin]

Mine goes in Monday for the new rear part numbered rear axles.

 

[G1eagle]

Mine goes in Monday for the new rear part numbered rear axles.

Are you having the clunk when you’re on/off gas or a rotational popping noise?

 

[Mr.C]

Mine goes in Monday for the new rear part numbered rear axles.

I’m curious to know if you have any clunking afterwards. Like I’ve mentioned, I still do, even though it’s improved around 75-80%. It’s still there.

 

[Mr.C]

Are you having the clunk when you’re on/off gas or a rotational popping noise?

Mine has always been when pressing on and off the gas.