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Discussion Starter #1
Hi everyone, i have a 2009 rhino 700, i have been racking my brain and replacing every part i can think of but i cant seem to track down a rear end noise. The noise sounds like a popping, clicking noise when you turn certain ways, back up at times and even going forward. I have replaced both cv shafts, all bearings bushings ect., the rear driveshaft boss, even went as far as to replace an entire knuckle because there was still a slight bit of play after the bearings were replaced. The entire rear end is tight, i put bigger bolts in the diff housing there's no slop there. This is driving me crazy. Any input any ideas anything at all to go on would be amazing, i for the life of me cannot think of anything else to try. the rear diff fluid was as clean as the day i changed it no metal in it no chunks. Im at a total loss.
 

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Sounds like a cv joint, you said you replaced the cv shafts do you mean axles? In that case you would have found a broken cv, with everything you've done I'm at a loss as what to check next good luck.
 

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I did change both rear axles, that was the first thing I did because I did have a torn boot on the drivers side. I changed it and the sound didn't change or go away so I changed the passenger side too thinking maybe the sound was playing tricks on me because it always sounded like it came from the drivers side. I appreciate your comment but I am definitely at a loss with this. The only other thing I can think to try at this point is to build or buy a diff brace and see if that does anything .
 

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So i have been doing all the reading online i can, and i think maybe the axle i got is junk, it was one off of amazon and what im wondering is has anyone else ever used a cheaper axle and had issues right from the start with it? Thats literally the ONLY thing i can come up with im ready to pull my hair out with this noise.
 

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I bet you got a bad one. I have replaced many axles and that sound you describe is what it has always been for me. Drive it and have someone back there listening to try and pinpoint the sound..I would back up and turn at the same time to put stress on the joints. May help to see which side and where it is coming from. Good luck and let us know the results.
 

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Check with intro2rhinos on here he parts out rhinos I would buy a used stock one than some questionable aftermarket one.
 

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I’ve had the same issue. Couldn’t find and thought it was a bad differential. Installed new after market but wasn’t the rest end. Then I removed and inspected the rear axles. They ad some wear so I purchased new after market complete with new CV joints. Installed and had problems with popping sounds. I assume CV joints on new axles are bad. I would recommend buying new factory axles complete with CV joints. I willl be replacing mine on my 2006 660 when I have time and will toss the after market ones!
 

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I have an OEM axle coming today will get it put in and see what happens. If it's still making the noise the only other thing i can possibly think of is bad diff bearings. I'm not a mud guy and don't abuse the machine it has roughly 4,500 miles on it I wouldn't think the diff bearings would be bad the oil i drained out was clean with almost zero signs of metal in it. When I get the new axle in ill let everyone know what happens. Thanks for all the replies and ides
 

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Here's some advice on your rear popping noise. First off, I've got an off road tour business with abou 15 or so Rhino's in our fleet.
To eliminate what the issues are, I suggest following the troubleshooting tree.
Always check for fluid in the differential and it's topped off. If you're unsure of the quality, then it should be changed.
Check for leaks @ all 3 diff seals. Any consolidated amour of dark dirt or sand could be signs of a potential leak. Next, the rear CV axle assembly should be checked. Shake them forward and to check for sloppiness/exsessive play. (DO NOT SLIDE IN AND OUT)
Next reach in and check the rear drive shaft by shaking it side to side. (DO NOT SLIDE IN AND OUT)
This is to check for excessive play.
Next is to inspect the brake Caliper hardware and brake pads. Look for uneven wear or gouging (you will see as you get further)
Here is a very important task.
Inspect the rear diff mounting hardware. Yamaha did not use suitable mounting hardware. The diff mounting holes in the casting was an 1/8" larger than the mounting bolts and the diff chassis mount gets wallowed out.
This creates the popping, grinding, and clicking.
You ask "Why Did You Sugest The Troubleshooting Tree?....)
That tree keeps you from jumping around and missing something while doing an inspection of your machine. Gouging of the brake pads and or brake rotor will explain the grinding noise. The clicking is the CV axle assembly which is why the diff seals are inspected.
The rear diff becomes loose due to the unmatched holes in the chassis mount and diff case. This kicks the rear diff in crazy directions and hence the noise sound primarily on the drivers side and then the noise moves. You will want to upgrade the bolts I believe to 11m or 12m bolts. I will post more about what sizes when I get to my shop. You will need to buy a drill bit to clean up the holes. Lastly we've been torquing the bolts to 75 ft lbs. Some say 65, we've had luck with 75 ft lbs.
Be sure to drive the machine straight to the work area to better center the diff for a better alignment.
 
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