[Trailfreak]

I’ve had a clunking noise coming from my front differential for a while now, mostly when I come to a stop. Yesterday, I took the differential out to see what’s wrong and order replacement parts, but other than pinion gear having the most visible wear, I can’t figure out what I need to replace everything looks fine. Can someone with experience on this look at the photos and see if something is worn and should be replaced.

I replaced my front axles last year, the old ones had ripped boots and I thought that’s what was clunking but the clunking continued after replacing the axles.

2001 Rancher ES 4x4. The machine has been used for snow plowing most of it’s life, I thought maybe some of the parts inside the differential have worn, so I decided to take it apart and see.

Thanks.

 

[wheelsquad]

I’ve had a clunking noise coming from my front differential for a while now, mostly when I come to a stop. Yesterday, I took the differential out to see what’s wrong and order replacement parts, but other than pinion gear having the most visible wear, I can’t figure out what I need to replace everything looks fine. Can someone with experience on this look at the photos and see if something is worn and should be replaced.

I replaced my front axles last year, the old ones had ripped boots and I thought that’s what was clunking but the clunking continued after replacing the axles.

2001 Rancher ES 4x4. The machine has been used for snow plowing most of it’s life, I thought maybe some of the parts inside the differential have worn, so I decided to take it apart and see.

Thanks.

How do the bearings all feel in the differential?

 

[Trailfreak]

I’ve had a clunking noise coming from my front differential for a while now, mostly when I come to a stop. Yesterday, I took the differential out to see what’s wrong and order replacement parts, but other than pinion gear having the most visible wear, I can’t figure out what I need to replace everything looks fine. Can someone with experience on this look at the photos and see if something is worn and should be replaced.

I replaced my front axles last year, the old ones had ripped boots and I thought that’s what was clunking but the clunking continued after replacing the axles.

2001 Rancher ES 4x4. The machine has been used for snow plowing most of it’s life, I thought maybe some of the parts inside the differential have worn, so I decided to take it apart and see.

Thanks.

How do the bearings all feel in the differential?

They feel smooth and no side to side play. It was very clean inside.

 

[wheelsquad]

I’ve had a clunking noise coming from my front differential for a while now, mostly when I come to a stop. Yesterday, I took the differential out to see what’s wrong and order replacement parts, but other than pinion gear having the most visible wear, I can’t figure out what I need to replace everything looks fine. Can someone with experience on this look at the photos and see if something is worn and should be replaced.

I replaced my front axles last year, the old ones had ripped boots and I thought that’s what was clunking but the clunking continued after replacing the axles.

2001 Rancher ES 4x4. The machine has been used for snow plowing most of it’s life, I thought maybe some of the parts inside the differential have worn, so I decided to take it apart and see.

Thanks.

How do the bearings all feel in the differential?

They feel smooth and no side to side play. It was very clean inside.

That's good. How about the drive shaft splines at the front of the motor? A-arm bushings, wheel bearings, and shock mounts all tight too?

 

[Trailfreak]

How do the bearings all feel in the differential?

They feel smooth and no side to side play. It was very clean inside.

That's good. How about the drive shaft splines at the front of the motor? A-arm bushings, wheel bearings, and shock mounts all tight too?

It clunks when I stop after riding. I’ll check the wheel bearings and drive shaft splines.

I have Progressive 512 shocks, 1” longer.

 

[retro]

Check the knuckles for bad ball joints, the upper & lower A-arms for bad bushings and the brakes (& brake adjustment) as well while you have it apart. The front diff looks fine to me.

 

[Trailfreak]

Okay Retro I’ll check those. Thanks.

I was thinking that if the machine is stopped and in neutral there is nothing turning the drive shaft and nothing turning inside the differential so it shouldn’t clunk or click, or could the differential assembly still be moving somehow and making the clicking sound? Just wondering.

 

[retro]

I thought this clunk was coming from a moving Rancher while braking to a stop... Are you saying there is a clunk coming from it while it is completely stationary?

This probably isn't relevant to your issue, but I noticed a clunking sound on the 450 Foreman I had just after I brought it home. As I looked the bike over I found that someone had left out two bolts (of three) out of the oil drain plug guard under the motor, on the bottom of the skid plate. That guard was bent back and doubled over hanging by one bolt and was slapping the skid pan on occasion, making a loud noise. I bent it back where it belonged, put the bolts back in it and the clunk disappeared.

Sources of clunks & noises can be pretty simple sometimes.

 

[Trailfreak]

Yes, it clunks after I stop and get off the machine, it does not clunk while riding. I thought it could be coming from the Superwinch because the noise was coming from that front area, I took the winch wire off the battery and it still did it. It only does it for a few seconds that’s why I thought it was coming from the deferential maybe something inside is still turning after I stop and it needs fixing. The noise does not seam to come from the wheel areas.

I’m away for a week, I’ll work on it when I get back. I’ll start by putting the differential back, as it’s still in good condition, as you noted.

I’ll look around, like you said it maybe something simple. I will also take some of the plastics off the front and sides after I reinstall the differential so I can better hear where the noise is coming from. Maybe it’s more inside the front engine cover, oneway cluck maybe? Don’t know if those clunk.