Pioneer 500 front end noise

[Snigema]

Recently had front differential case replaced under warranty due to a constant fluid leak. Now it seems like there is noticeable "clanging" noise from the front end. It sounds like something is loose and hitting the frame because I can feel it in the floor board. It doesn't do it all the time but mainly does it on rough terrain. If I grab both front axles at the same time, I can move them front to back slightly? Is this normal? I feel like this movement is what I'm hearing...

 

[Admin]

 

[Code54]

Movement is normal. The noise is not. May want to check the shaft the runs from the diff back. I am wondering if they did not get it seated correctly and it is bumping from time to time

 

[Snigema]

Thanks! That may very well be the issue! I'll check it out. Thanks

 

[Code54]

Anytime - also make sure the diff mounting bolts are in tight while you are working on it.
Good luck

 

[Hondasxs]

+1.
Always recommend checking behind the dealer if you are able.

 

[Snigema]

So, after riding this weekend I determined that the noise is only present when in 4 wheel drive! Any ideas? I've checked every piece of linkage and suspension part I can get my hands on and can't find anything loose.

 

[Snigema]

Heads up to anyone with a Pioneer 500! I finally figured out the noise coming out of my front end. The bolt that holds the differential case to the frame in the top rear location of the diff, is the wrong size bolt for the hole. I went back to my dealer and we discovered that a pioneer on their showroom floor had the same problem. Apparently, during assembly , Honda over tightens these bolts to mask the problem. If a service tech removes the front diff and then re-installs according to factory specs, the front differential housing will not be held tightly to the frame. The very odd part is that the correct size bolt was a SAE .5" bolt! The .5" bolt fits perfectly in the mounting hole and eliminated all movement that was present with the factory 12mm bolt. I contacted Honda and my dealer and have been sorely disappointed in how they have handled the situation up to this point!

 

[William]

So replace it with an SAE .5" bolt the same length?

 

[Snigema]

So replace it with an SAE .5" bolt the same length?

Yep, the new bolt fits like a glove!

 

[hambone]

Thanks ! I have noticed a noise like that before. I will check it out.

 

[dominator]

Any idea what The length of that half inch bolt should be ?

 

[HUCK]

Ummmm .. half inch ?

 

[alloutdoors]

great find!

 

[70Bones]

Guys, this refers to the 2015 models. Don't panic until someone figures out if Honda fixed the problem since then.