These front diffs are pretty tough and hard to hurt. Only thing that will hurt them quickly is water on the fluid or a bad seal. As for the noise check the front drive shaft yoke and u joint at the front diff. I have went through 2 of them. The u joints are also a problem area as well as carrier bearing. Any of these can cause front drive line noise when not under load.

 

Front axle inboard spline could be worn out, you can grab the center shaft bar try to move it and see if there is any play on the inboard joint.

 

Its very odd that the noise goes away in 4WD. Generally I would suspect the pinon bearing or carrier bearing but since it goes away in 4wd it has me thinking something to do with sprague cage. Possibly broken H Clips for the rollers.

 

Long story short, the dealership wanted to take a 2nd look. Dropped it off wednsday and they called today and said the prop shaft was the issue. When i get back to town next week i will see if that was it

 

That's very possible, I had my front prop shaft bend right at the yoke and it created quite a vibration and tore up a couple Pinon bearings before I caught it.

 

The drive shafts are a big issue in the rs1. Normally the front shaft yoke on the drive shaft spreads and will bust or the yoke that goes into the front diff gets all wallowed. My dealership I use has had to actually replace 2 frames under extended warranty because when the drive shafts broke up by the diff it beat the hell out of the frames.

 

Took my machine out for a rip the other day.
Still same problems, rattles under load in 2wd from the front area, makes an aweful vibration sound and feel when under acceleration in 4wd. No vibration in 2wd, and no jingling rattles in 4wd.
Best part is they put my clutch cover on wrong and compromised the seal right in the bottom lowest point.
I am done with my local dealer and unfortunately they own the next one closest to me as well.

There has to be a problem with the front diff pinion.

 

How many miles do u guys have on ur rs1's? I have 3,400 miles on mine so far n this is the 1st I have heard of this.

 

I only have 1200KMs

 

how is it running since you got it back from the dealer???

 

Front end still sounds like crap.

Took it out for a run this last weekend and still "jingles" in 2wd, then makes a grinding noise you can hear and feel when in 4wd.

Never at the same time, it is either or depending if you have the front diff engaged or not

 

this may sound stupid but when you put it in 4wd is it all the way in 4wd? maybe its not fully in gauged just saying. I hear something like a jingle too but its coming from my tie down rings in the bed bouncing around. I was driving mine most of the day today n will be again tomorrow. I myself only use 4wd when I absolutely have too. But I will be using it a lot tomorrow just to see if it vibrates ect.

 

Did you ever figure out the noise? I have the exact same issue but it's in my XP4 turbo that I did the RS1 diff swap a couple months ago. Has made the same sound in 2WD only, since the first day with the brand new diff.

 

Did you ever figure out what was wrong with yours

 

Lift all 4 wheels off the ground and run up a little speed. See if the jingle is still there. And make sure the front wheels aren't trying to turn.

 

Mine is doing the exact same things I've tried to brand new rs1 riffs and a brand new rhino drive line and cant figure it out

 

I had similar symptoms that ended up being a U-joint.

 

I broke one ear off rear universal joint. Pulled prop shaft only to find front yoke was starting to bend...................................................... but I'm not actually easy on equipment