Clunk discussion

[Mr.C]

Same here, the dealer did re torque my axle nuts. That lasted about 20 miles or less. I guess I just need to start barking.

 

[oneal]

On 10/10/24 I posted the above response. I believe the first two items in the list are actually the same issue. In July I had a clunking noise (one clunk) that only happened when letting off the gas. My dealership tightened the nuts on the rear axle and the noise disappeared. About 2 weeks after that visit I started hearing a faint rotating knocking sound related to the drivetrain (meaning the knock slowed as I was slowing) when I let off the gas (25 or less), it was especially prevalent when letting off the gas going down a hill. This is all street driving so you can hear just about everything when the radio was off. I knew the dealership wouldn't do much about it so I kept driving figuring the knock would get louder. A month after it started, it continued to get louder so I took it into the dealership and they tried the "lock tight" fix. It didn't help. I drove it for another month or so before I took it back in. They convinced Polaris to replace the all driveshafts. That didn't work either. I drove it for another month or two before I took it back in. This time the dealership convinced Polaris to replace the rear axles. They put on the new axles along with the "lock tight" fix. The noise is no longer there (although I've only driven it 20 miles or so). They want me to report back if I start to hear anything.

Our machine has 5300+ miles on it. We use it to run errands, trail ride, technical trail riding, noxious weed spraying and any other excuse to ride it.

The following was over a 5 mos. period.

• Single clunk when letting off the gas, 25 mph or less.
  • fixed by tightening the rear axle nuts
• Rotating noise started 2 weeks later when letting off the gas, 25 mph or less
  • could hear the noise better on the driver's side with the window down
  • mainly prevalent when letting off gas going down a hill
  • they tried fixing with lock tight, didn't work
• Noise started to get louder and starting knocking when accelerating and driving at constant speed
  • could hear the noise better on the driver's side with the window down
  • the knock was generally louder when just starting to drive and when it was colder outside
  • they replaced the driveshafts, didn't resolve anything
• Noise continued to get louder and more prevalent
  • could hear the noise better on the driver's side with the window down
  • I removed the interior driveshaft cover to see if it was louder, I couldn't hear any of the knock coming from that area
  • they replaced the rear axles along with the lock tight fix, the knock is gone (for now)

You kept good notes.
Early on Polaris told one of the dealerships I visit they were not doing anything but the Loctite but with yours it sounds like they are changing and going to actually use new parts for the repair. This is great news

 

[AVI8OR]

OK, I called Polaris at 1-800-765-2747 and told them my problem. He said I need to have my dealer start a tech case or a claim case and he gave me a 7 digit access number so I can open it up and find out anything they come up with on the problem. He is also sending me an email directing me on how I can get this started. I will attach it here when I get it. He recommends everyone do this, because the more they get, Polaris will know how serious the problem is and this helps them correct it. I don't know, but this is a start.

This type of proactive engagement is exactly what I am talking about! I'm glad you called Polaris. I suggest those of us with the issue who are left without any resolution also call. Keep poking the bear and we'll get a response. We would hope so anyhow. This being a flagship Ranger for Polaris, us owners can either make or break the future of their sales. Seams like a no-brainer to me!

 

[gdh]

I had replaced the rear diff. fluid by dealer hoping that if there was problem evrything would be covered. Well 100 miles later the clunk came. Now dealer did the loctite fix and it has stopped. But asked dealer if Polaris comes with a better fix would it be covered they said yes. It is winter in WI so I am not riding it much will see if it comes back.

 

[AVI8OR]

Had another thought, I'm hoping each dealer that sees these issues is also contacting Polaris. Not just for replacing the components under warranty, but to press them that this seems to be a more than just a random issue. Wondering if an updated axle with tighter tolerances would be the likely fix....

 

[Johnnie]

I called my dealer today and he had one of his mechanics call me back. Long story short I told him about rear axle clunk. He said he hasn’t heard about it. Said to bring it over and he would sure look at it. Problem is I’m 300 mile round trip and really don’t have time to make 2 trips if he wanted me to leave which I would need to for them to really go thru it. I do have a 2 year warranty and my dealer said if anything should break it would be covered with a fifty dollar deductible starting on 2nd year of warranty. Hopefully they report this to Polaris.

 

[Rockotoby]

Here is the email from Polaris telling me how to get this started.

 

[Rockotoby]

I called my dealer today and he had one of his mechanics call me back. Long story short I told him about rear axle clunk. He said he hasn’t heard about it. Said to bring it over and he would sure look at it. Problem is I’m 300 mile round trip and really don’t have time to make 2 trips if he wanted me to leave which I would need to for them to really go thru it. I do have a 2 year warranty and my dealer said if anything should break it would be covered with a fifty dollar deductible starting on 2nd year of warranty. Hopefully they report this to Polaris.

I would tell them to report it to Polaris

 

[bbieb]

On 10/10/24 I posted the above response. I believe the first two items in the list are actually the same issue. In July I had a clunking noise (one clunk) that only happened when letting off the gas. My dealership tightened the nuts on the rear axle and the noise disappeared. About 2 weeks after that visit I started hearing a faint rotating knocking sound related to the drivetrain (meaning the knock slowed as I was slowing) when I let off the gas (25 or less), it was especially prevalent when letting off the gas going down a hill. This is all street driving so you can hear just about everything when the radio was off. I knew the dealership wouldn't do much about it so I kept driving figuring the knock would get louder. A month after it started, it continued to get louder so I took it into the dealership and they tried the "lock tight" fix. It didn't help. I drove it for another month or so before I took it back in. They convinced Polaris to replace the all driveshafts. That didn't work either. I drove it for another month or two before I took it back in. This time the dealership convinced Polaris to replace the rear axles. They put on the new axles along with the "lock tight" fix. The noise is no longer there (although I've only driven it 20 miles or so). They want me to report back if I start to hear anything.

Our machine has 5300+ miles on it. We use it to run errands, trail ride, technical trail riding, noxious weed spraying and any other excuse to ride it.

The following was over a 5 mos. period.

• Single clunk when letting off the gas, 25 mph or less.
  • fixed by tightening the rear axle nuts
• Rotating noise started 2 weeks later when letting off the gas, 25 mph or less
  • could hear the noise better on the driver's side with the window down
  • mainly prevalent when letting off gas going down a hill
  • they tried fixing with lock tight, didn't work
• Noise started to get louder and starting knocking when accelerating and driving at constant speed
  • could hear the noise better on the driver's side with the window down
  • the knock was generally louder when just starting to drive and when it was colder outside
  • they replaced the driveshafts, didn't resolve anything
• Noise continued to get louder and more prevalent
  • could hear the noise better on the driver's side with the window down
  • I removed the interior driveshaft cover to see if it was louder, I couldn't hear any of the knock coming from that area
  • they replaced the rear axles along with the lock tight fix, the knock is gone (for now)

Just wanted to report back on the axle/lock tight repair. I've put 800+ miles since the last update and all is well. No noise coming from the axles.

 

[Mr.C]

Just wanted to report back on the axle/lock tight repair. I've put 800+ miles since the last update and all is well. No noise coming from the axles.

That’s good to hear. I’m taking my ranger into the dealer in a couple weeks for the door handle/latch recall. I’m gonna bring it up to them again.

 

[oneal]

Just wanted to report back on the axle/lock tight repair. I've put 800+ miles since the last update and all is well. No noise coming from the axles.

Great news, gives others hope Polaris will do the right thing. Thanks for sharing this.

 

[wagers]

I too after 600 miles now have the rear clunk. Took to my dealer and Polaris did the loctite suggestion. The local tech argued that it sounded more like backlash and shims are on the way.

 

[Clubin]

So, food for thought. The rear axles have another part number. I was buying a spare because I spun a boot. My current ones were changed from the stock ones. The newest ones have a totally different part number.

 

[Mr.C]

So, food for thought. The rear axles have another part number. I was buying a spare because I spun a boot. My current ones were changed from the stock ones. The newest ones have a totally different part number.

Hmm, so you think maybe they’ve changed or updated the axles due to the clunk? I’m gonna bring it up on the 5th when I take mine into the dealer. Every time I see them, I’m gonna be bringing up the rear clunk.

 

[Clubin]

Hmm, so you think maybe they’ve changed or updated the axles due to the clunk? I’m gonna bring it up on the 5th when I take mine into the dealer. Every time I see them, I’m gonna be bringing up the rear clunk.

There would be no other reason to change the part number.

 

[Clubin]

Hmm, so you think maybe they’ve changed or updated the axles due to the clunk? I’m gonna bring it up on the 5th when I take mine into the dealer. Every time I see them, I’m gonna be bringing up the rear clunk.

The new ones are available in 2 months. So don’t rush.

 

[Mr.C]

The new ones are available in 2 months. So don’t rush.

I’d think if this was gonna be Polaris’s fix, they’d send out a notice of some kind. Or I would hope anyways. I wonder if it’s not a change in part number due to a change in supplier/manufacturer. I’ve seen that alot in work, part numbers get superseded for what seems no reason at all.

 

[oneal]

I’d think if this was gonna be Polaris’s fix, they’d send out a notice of some kind. Or I would hope anyways. I wonder if it’s not a change in part number due to a change in supplier/manufacturer. I’ve seen that alot in work, part numbers get superseded for what seems no reason at all.

I would agree, they have likely identified the tolerance or measurement issue and have deleted the old parts and associated number.. At least let's hope.
Still a mystery why there is a relatively small number of us that got the clunk.

 

[Rockotoby]

After the fix with loctite, they said the clunking went away, and for the front suspension clunk, Polaris told them it was normal, now I was driving it around in the yard, and my right axle fell out of the rear end. I looked at the left axle, and it was starting to come out too. Just took it to the dealer and told them and said they might have to put new clips on the splines to hold them in, and that I could see the lock tight chewed up on the splines. Told them the knocking started about 2 hours after I got it back the first time. He said he was going to try and get me new axles. I don't know if he knows something or not, but I will keep you posted.

 

[Clubin]

After the fix with loctite, they said the clunking went away, and for the front suspension clunk, Polaris told them it was normal, now I was driving it around in the yard, and my right axle fell out of the rear end. I looked at the left axle, and it was starting to come out too. Just took it to the dealer and told them and said they might have to put new clips on the splines to hold them in, and that I could see the lock tight chewed up on the splines. Told them the knocking started about 2 hours after I got it back the first time. He said he was going to try and get me new axles. I don't know if he knows something or not, but I will keep you posted.

Lol. I mean it’s not funny, but I had the exact same thing happened with a new set of axles that the dealer installed. I had to remove them and open up the circle clips.