rattle in front differential?

Geo-TH,In · Aug 10, 2013

I have a rattle in the front differential of a kaw mule 4010? Dealer had it for 2 weeks, shimmed it. Still have a rattle when slowing down in 2 wheel drive. Problem goes away in 4 wheel. I first thought my problem was a loose body panel vibrating, but it's the front differential talking. Mule is only 6 month old and 60 hours. The oil in diff looked like gray metal flake and it was changed at 25 hours.

Is this a common problem?

guido · Aug 10, 2013

Hello George Marsh,

The oil looking like metal flakes? Not a good thing. You may have a bearing gone!, NOT GOING bad. Sounds like the pinion lost its preload, and it is slopping back and forth. Under load it stays in and takes up the slack. Second opinion is warranted!, mine is just a guess!

Guido.

Dalex · Aug 10, 2013

I'm likin' what Guido's sayin'....

Geo-TH,In · Aug 10, 2013

Dealer had it for 2 weeks. Just got it back today. Only hear vibrations after running full speed, getting off the gas, and it slows down to about 3 mph. They shimmed it and said they had it tighter and within specs. It is still under warantee until the end of the year. Going to wait and see if it gets better. I think there is some gear wear because it wasn't put together right the first time. Will keep an eye and ear on it.

guido · Aug 11, 2013

Hello George Marsh,

Shimming took care of your first and only problem.
Now you have a drive line issue. My guess is they did not clock the drive axle correctly. The vibration will only happen at certain R.P.M.'s.
Another guess on my part,

Guido.

Hobo,NC · Aug 11, 2013

(quoted from post at 06:57:15 08/11/13) Dealer had it for 2 weeks. Just got it back today. Only hear vibrations after running full speed, getting off the gas, and it slows down to about 3 mph. They shimmed it and said they had it tighter and within specs. It is still under warantee until the end of the year. Going to wait and see if it gets better. I think there is some gear wear because it wasn't put together right the first time. Will keep an eye and ear on it.

And it will probably never be right...

Differentrials are not forgiving you have one shot at setting it up correct if you miss it you lost it are put this way your are stuck with the noise... There may be no set up at all I would have to see a break down on it... I don't like what you stateded on the condition of the fluid I would want a new front diff...

On new stuff I will give them one shot to fix it from their they can replace it...

Anonymous-0 · Aug 11, 2013

Time to Rattle the dealer, I feel he's going to be the bigger problem.

Geo-TH,In · Aug 11, 2013

Mule is headed back to the dealer. Not only is the front differential talking so is the 4x4 transfer box. Sounds like something is broken and getting in the gears. I may have drive it and blow up the transfer case if they don't fix it.

retired farmer · Aug 11, 2013

You could have got a lemon.

Jack345 · Aug 11, 2013

Take a magnet and run thru the lub ... if its serious filings will be on magnet. also it may smell slightly off.I'm sure the dealer changed out lub when work was completed but just in case.

Geo-TH,In · Aug 12, 2013

I agree, after the rear transfer case started making a loud popping sound every 1000 ft or so in 4 wheel.

rattle in front differential?

Geo-TH,In

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guido

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Dalex

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Geo-TH,In

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guido

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Hobo,NC

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Anonymous-0

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Geo-TH,In

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retired farmer

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Jack345

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Geo-TH,In

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