Just under 7000 miles with a new alternator bracket and I had an oil leak from the rear camshaft plug. According to the overhead I can get from 13 mpg towing 5000 lbs at 75 or I can get 21 mpg empty at 55. My first diesel and I love it. 8)

 

[quote author=sawboywv1 link=board=20;threadid=15792;start=15#164110 date=1059169191]<br>??????? the fill hole is the only reference for checking fluid level. it also clearly states in the owners manual to check fluid level from file hole. i can't believe there are set-up issues, AA has manufactered axles for years. and for alot of different manufactures. although anything put together with hands is subject to a problem every now and then!<br>[/quote]<br><br>I spoke with the quality assurance manager responsible for the DC/AA relationship to learn what I am reporting on this forum. No, the fill hole is not the correct indicator of &quot;full&quot; fluid level on the 11.5&quot; (2500/3500) axles -- this was a real mistake on AA's part (in my opinion), in that they manufactured several different axles (not just the 11.5&quot with the came gear casing -- and all with the same fill hole location. you are right that the whole world (and the manual) specifies that the fill hole is the correct level indicator, but AA in all their wisdom shipped axles with the right amount of fluid but showing &quot;1-2 qts&quot; low if you look at the fill hole. In other words, the fill hole is too high.<br><br>different gears in different geometries displace different amounts of fluid and result in different fluid levels with the same amount (volume, # of quarts) of fluid.<br><br>If you can't believe there can be setup issues then consider the complexity of managing a production assembly line, bringing on a new one, personnel changes, international relationships, etc. yes, there were quality problems with the early 03 axles, associated with a particular assembly plant. And gear set-up is not trivial either -- a manual procedure must be performed on every axle by a skilled human being who has to make desicions. Indeed, filling the axle with a certain prescribed volume of fluid, ignoring the fill hole position, is a far more repeatable and accurate manufacturing process than gear setup. You can dump in x number of quarts of fluid from a bulk container with a robot or a monkey for that matter. ;D<br><br>I'm not sure whether gear setup, or parts quality, or both, were the issues early on with the AA axles. I think it was pretty impressive for AA to admit these to me, while assuring me that these issues were ironed out and associated only with a particular new assembly plant. Without regards to that, however, compounding these early quality problems was the issue of fill level. insufficiently educated DC field service technicians improperly diagnosed gear problems as low fluid level. In some cases, the put in the wrong fluid (mixed std with synthetic) and in some cases even put friction modifier in. The AA axles must have only pure 100% synthetic with no friction modifier, even for the LS.<br><br>I think it was a stupid move on AA's part for shipping an axle where the fill hole is not the correct level indicator. Just too much confusion. They should have shipped them filled to the brim, but with pure synthetic lube ($$$) they were (in my opinion) probaby saving some manufacturing dollars by:<br><br>1. preserving a highly automated, highly accurate and repeatable process for filling several different axles within the same production line with the right amount of fluid. that is, they were filled with x number of quarts, rather than requiring human feedback or decision making.<br><br>2. the cost of 1-2 quarts of synthetic gear lube.<br><br><br>worse yet, for the trucks' 03 field service they didn't get the word out (or there were communication issues within DC) to field technicians with regards to this. Hence the earler complications involving the incorrect fluid and the improper use of friction modifier.<br><br>My recommendation is to have the dealer:<br><br>1. research what the correct fluid is. they should call the star line if necessary, as the correct information from AA has been communicated to the star line. The correct part number is 100% synthetic, unlike the fluid shipped in the earlier 2nd gen trucks with Dana axles. No friction modifier is to be used in the LS axles.<br><br>2. fill-er up to the fill hole. the extra fluid is just better cooling, all bonus and no downside. <br><br>I sure wouldn't want to drive around without fluid up to the fill hole, in spite of all the cool information AA gave me. Its just too wierd, and a recipe for more confusion down the road. Oh, and if your dealer won't do the above, have them at least do step 1 and you can do step 2. I understand also you can use one or more of the major 100% synthetic 75w-90 gear lubes, but I have not personally verified that.<br> <br>