Clunking/Binding sound

[countrycar]

Hey guys, just wondering if anyone has dealt with this yet. I have a 2007 610 mule with 54 hrs on it, and it has a bad clunking/binding sound that's coming from the front end. It only does it in 2 wheel drive. When it starts this clunking/binding sound, if I reach up and put in to 4X4 it goes away. Sometimes if I drive in circles and or figure 8's it seems to go away. So I suspect that it is getting caught between 4x4 and 2 wheel drive, or maybe an axle isn't releasing/disengauging in the front end. Sure would like to figure this out. Does anyone have any experience or info on this. Thanks in advance.

[DeltaMule]

Having the same problem but in reverse. Mine does this in 4wd and not 2wd. Hope we get answers. (2009 4010)

[countrycar]

I'm gonna try the local Kawasaki dealer where I purchased the mule for some answers. I'll let yah know if I get any info.

[countrycar]

Originally Posted by DeltaMule

Having the same problem but in reverse. Mine does this in 4wd and not 2wd. Hope we get answers. (2009 4010)

Well I went to the Kawy shop, they said that it's not a common problem with these mule's. They're gonna need to check it out though. I won't be able to get it to'm for acouple of weeks though. The more I think about it though it keeps feel'n like the ft pas side axle isn't disengauging when I take it out of 4X4. Maybe a rapp with a rubber malet, or a hammer and a 2x4 to protect it from damage might dislodge it. Just think'n out loud at this point because I don't wanna pay to get it looked at. Anyhow I'll stay in touch regardless and let yah know what I find out.

[John Taylor]

Just hope its not contagious and mine gets it.

[RCW]

The axle does not shift out at the front differential, but at the main transaxle.

The front differential is preloaded with frictions on each side of the internal bevel gears that drive the front axles. It is a means to limit the slip so they can pull with both front wheels.

Usually, what happens is the front differential oil is either no changed when it should be, or the wrong oil is used and those frictions lock up to the sides of the bevel gears. Then when you turn a corner and one wheel tries to speed up to compensate, the clutches make a nasty clicking noise.

No big deal, just clean out the old oil, refill with the correct replacement, and add a bit of friction modifier for limited slip differentials, then go turn in circles for while and the noise will stop.

If by chance your main four wheel drive linkage is not aligned and you simply are not shifting all the way out of four wheel drive, there are lines on both the bracket and the shaft that are lined up to bring it back to where it belongs.

Lastly, if someone were uninformed enough to shift in and out of four wheel drive on the fly, then you may have broken components in the transaxle.

[countrycar]

Originally Posted by RCW

The axle does not shift out at the front differential, but at the main transaxle.

The front differential is preloaded with frictions on each side of the internal bevel gears that drive the front axles. It is a means to limit the slip so they can pull with both front wheels.

Usually, what happens is the front differential oil is either no changed when it should be, or the wrong oil is used and those frictions lock up to the sides of the bevel gears. Then when you turn a corner and one wheel tries to speed up to compensate, the clutches make a nasty clicking noise.

No big deal, just clean out the old oil, refill with the correct replacement, and add a bit of friction modifier for limited slip differentials, then go turn in circles for while and the noise will stop.

If by chance your main four wheel drive linkage is not aligned and you simply are not shifting all the way out of four wheel drive, there are lines on both the bracket and the shaft that are lined up to bring it back to where it belongs.

Lastly, if someone were uninformed enough to shift in and out of four wheel drive on the fly, then you may have broken components in the transaxle.

Thanks RCW, gonna change the fliud first and see if that helps. I may fall into the later part of your post though . I have sifted my mule into and out of 2 & 4 wheel drive on the fly. It's never binded while doing this, so I guess I always thought it was ok. Now I know. Thanks Agian for the Help. CB.