I just bought a used P500, it makes the rear end noise when you let off, when you hold steady on level terrain, this isn't normal, even with straight cut gears it shouldn't make that much noise, I've checked the oil level and it's OK, everyone I've talked to has complained about this noise and so far everybody that has a P500 that I know owns this noise, I have checked the gear backlash and it seems normal, anyway miles are not going to fix the noise problem, mine has 2,200 miles and the noise is getting louder, I am waiting to hear from a service manager and see what he says, I like the P500 but this will be a burr under their saddle, bet next year it will be addressed.
I used a broom stick held to the rear end while it was jacked up, my wife ran it up to 20mph in 5th gear and the noise was in the rear end , I am going to continue to drive it but I want to remove the rear caliper and run it without the rear brakes and see if this makes a difference. I plan on draining the rear end and replace with Amsoil 80-90. I'll keep working on it until I can figure something out.
I just finished checking out the rear diff, the noise seems to come from the rear of the pinion shaft, I checked the parts fish and it shows a roller cage bearing, I'm betting this is the problem, with the way they angled the pinion shaft in relationship to the ring gear it looks like the bearing may be under too much stress for its size, just guessing
It is real, I'm a Honda guy and I've owned mini-trail 70, several trail 90's, Honda generators, 2 Rubicons, and now a very disappointing Pioneer 500, I called customer service and they said it's the first they have heard of this, REALLY? I'm almost sure that it's the cage bearing on the pinion shaft as that's where the noise is loudest, just too many complaints about rear end noise, look at the weird angle the pinion shaft is positioned then look at the ring gear, just doesn't look right to me, maybe I'm too old school, anyway I'll get to the problem and post what I find but it will have to wait until I'm done hunting.
Yes I know the previous owner, he and I are good friends, he takes care of his things, mostly drove this around town, came to see me in Colorado this year and sold me the Pioneer because he wanted the full size, I checked the diff oil, it is clean, don't know what to think, as you say time will tell
