Clunk discussion

[Mr T.]

Is this a problem only with the earlier '24 models or is it common in units produced later in'24? How about '25s? Looking at pulling the trigger on one and curious what to expect. Been through Polaris issues like this before with RZRs.

 

[Clubin]

Is this a problem only with the earlier '24 models or is it common in units produced later in'24? How about '25s? Looking at pulling the trigger on one and curious what to expect. Been through Polaris issues like this before with RZRs.

I had a 25 for a loaner. It started clunking after I had 400 mikes on it.

My axles were changed on my crew they were good for 500 mikes but it’s doing it again to.

I turn up the stereo you can hardly hear it. lol

 

[oneal]

Is this a problem only with the earlier '24 models or is it common in units produced later in'24? How about '25s? Looking at pulling the trigger on one and curious what to expect. Been through Polaris issues like this before with RZRs.

Ours is mid 24 with it but there are numerous early 24's that are clunkless. Clubins post above is the first report I have read from a 25, I figured they had corrected it.

 

[G-Dub]

Manny of us now have the "clunking" noise in the rear of our 1500. It is mentioned in many places on this forum with numerous different thoughts of where it originates and exactly what makes this annoying noise.
Coincidentally Polaris released a video on how to remove an axle and specific instructions on locking the outer spline with loctite.
Some have said checking the factory torque specs stopped theirs and others felt new CV's was the cure. Some feel their differential is disintegrating.
For me it's a real hassle to get mine to a dealership so I am hoping for a concrete resolution before I haul it in.
Please post your data with the following ;
Hours, miles, kmh's
Which side, both
Four or six seater
Low speed, high speed, or doesn't matter
Loaded, unloaded, doesn't matter
Is it simply a rotational noise or when you accelerate and let off
Any oil changes in the diff, any metal in the oil
What attempts have been made so far to resolve and did it work?

24 Ultimate Crew: 200 hours, clunk started at 100 hours on low speed acceleration/ decel., progressed to clunking under many situations. Sometimes I thought it could be rock under the skid plate/ panel. First dealer found nothing. Supposedly they checked axle torque and CV's. Basically told me to drive until it breaks. Not very confidence inspiring as I headed hunting in remote Idaho. At 205 hours itvdid indeed break. The left rear axle come out of the differential. This left me with no single wheel drive and other obvious problems. Local dealer replaced the axle under warranty. They showed me a picture of the axle hub on the differential end with two O rings that supposedly were not supposed to be there that had prevented the axle from seating fully. I have 10 hours post repair with no clunk (beyond suspension clunk mentioned by others). I do not believe they were aware of loctite "solution" when they replaced the axle. We will see. They did not instill a great deal of condidence on me. It didn't help that my battery was dead and allvwindows were left down in a bomb cyclone when I picked my 50k machine up. Needless to say I am not a big fan of Polaris at the moment. I should note. I did receive a $500 coupon frm Polaris for the problems I have been having with my "flagship" vehicle after several customer service calls to Polaris.

 

[Mr T.]

Thanks for the input guys. Enjoy your Thanksgiving !!!

 

[Js4fn]

I don’t have any clunk. When and what makes it happen how loud is it is it mostly on crew cabs ?

 

[Big Red]

I picked my 2 door up Jan 6th and have 2000 miles on it, so far no clunk. It would be nice if there was some definitive information on this problem.
Seems like most are in the left rear.
Some have said the splines are too sloppy and not tight enough. This aligns with the Loctite fix.
Now I hear there were 2 O rings that were not supposed to be there.

Does anyone really know exactly what the root cause of this issue is and possibly what date range may be affected?

 

[oneal]

Needless to say I am not a big fan of Polaris at the moment. I did receive a $500 coupon frm Polaris for the problems I have been having with my "flagship" vehicle after several customer service calls to Polaris.

I lost all my confidence years ago in them with a heat issue on the 700's, they never did publicly acknowledge or fix it. If you had a 700 that you rode much and did inot nstall a fan blowing on the engine you stood a great chance of the engine shrouds behind your legs having a hole melt through.
Looking like they are they are taking the same approach with this. We drove the 1500 and were wowed , I completly forgot about their reverse engineering approach and poor follow up.
We bought a first model year (2016) Honda Pioneer that had two issues, both were recalled and corrected before I knew what they were. It is almost 9 years old with 6K miles on it and runs great.
Shameful an American company leading innovation does not stand behind their product and have better customer treatment.

 

[oneal]

I don’t have any clunk. When and what makes it happen how loud is it is it mostly on crew cabs ?

Doesn't seem to matter if you own a single or double cab, both have reported it within this thread. It is truly random so hopefully you will be spared this annoyance.

 

[oneal]

Does anyone really know exactly what the root cause of this issue is and possibly what date range may be affected?

Unless Polaris decides to address it no one will hear their official diagnoses, if they released a bulletin without a plan to rectify, it could make a case for liability.
As for root cause, when I took mine apart the tolerances between the drive hub and the axle end splines were ridiculously loose. I performed the Loctite procedure on the splines and mine has been silent for about a month or about 30ish hours.

 

[Mr.C]

I took delivery of my machine in late March. My clunk started around 400-500 miles. Have had the axle nuts re torqued, and my dealer said the loctite fix was back pedaled by Polaris. Not really sure.