Wantabee, I'd also let DC know you're going straight to Transport Canada with a safety complaint against their product. SierraPhil and co., I'd do the same with DOT. From the sounds of it, DC has a pretty crap attitude. PDI used to be one more way of soaking the end customer for another grand...now they say it's to make sure the truck was assemble correctly??? ??? <br><br>I figure a bunch of calls in to DOT and TC will get DC moving with a recall and a BIG apology. Hey, these are mini-mortgages we're talking about!<br>

 

I talked to a friend who works at a Dodge dealer here in Chicago. He said that this is very common and he gets 2-3 in a week for complete o/hs. I asked him about the parts delay, he said that he does not know of any said that he has parts sitting in his dealer to repair them as they come in. I think u are getting the shaft wannabe... <br>For the couple of you that are just going to top off the fluid I would not. He said they are denying warranty claims on people who are adding there own fluid because they are not putting the correct fluid into it. He said there is also a Bulliten to add a friciton modifier to the fluid. just letting u know...

 

I don't advise adding fluid on 2003 vehicles delivered so far. Take it to the dealer so they have record of work order as evidence of a problem. You should be given a hard copy of the work order for your records. Keep all copies of work orders related to all problems.<br><br>As for denying warranty for adding fluid, federal law prohibits that in the US. Some dealers may try, but if you have proof that you added recommended fluids, they cannot deny warranty. Once you have added fluid yourself you have no evidence that it was delivered in a low condition. <br><br>Mandated Recalls don't happen unless a threshhold is reached, usually more than 5%. So far we know of only one total failure.<br>low fluid levels with resulting noise are not as yet failures. <br><br>My servicing dealer says there is no problem, repairs will be made under warranty. Don't draw and shoot the wrong guy.<br><br>Who assembled the axle, American Axle? Don't you put the correct lube in a finished component to protect parts in storage. DC may not be to blame.

 

I just got off the phone with my service manager. We have American Axles in our trucks, not Dana. This was stated above too. Mine is the 11.5&quot;. He checked this morning with STAR Center, I think its a tech info center for DC.? (I was on the Metro subway in DC and had a lousy cell phone connection). Anyways, for my 11.5&quot; American Axle, the correct fluid level is approx 3/4&quot; to 1&quot; below the bottom of the hole. He explained that if the level is higher than that the fluid will blow out the vent on the top of the housing. My level is about 3/4&quot; below the hole (looking at my pinky). Could the owners manual be wrong?? I'm convinced I'm ok then. I'm securing from General Quarters and re-stowing all gear.<br><br>In SierraPhils orig thread, the user Nigel also reported the 1&quot; level below the fill hole.<br><br>For wannabee, I've been known to get in front of the appropriate face and do some micro-managing for them until they came around to my way of thinking and/or finding parts. I&quot;m sure they'll take good care of you.

 

I was contacted by the dealer where my truck is being repaired...the service manager checked with enginering department of DC...the proper fluid levels for this axcle is 3/4 of a inch below the fill plug. They are apparaently saying now that my axle had the correct level of lubricant....it was the bolt that holds the rear hub that failed that caused this incident. Apparenly when the tire was taken off, the bolt was shread into many peices. Engineering is looking into the matter....we are going to have to give DC time to investigate and determine exactly what caused the part failure. Given my background in law enforcement...I felt obligated to report this incident to Transport Canada's Transport Safety Board (TSB)....to ensure this incident is fulling investigated...as not only did the bolt holding the wheel assembly fail....the studs holding the wheel were also sheared off and the side axle and housing was destroyed....this could have caused a major accident if the wheel locked up or the tire and hub fell off.The TSB will speak with their Americian counterpart in their investigation to ensure that this was an isolated incident. Hopefully there were no others...but if there were, obviously we have a legitimate safety concern for our families which must be addressed.<br><br>I will keep you informed as this progresses. I never dreamt in a million years that buying a new vehicle would be so stressful<br><br>Wantabee

 

Bulabula, I stuck my pinkie in to check and it came out dry. That is when I took a 10 gauge copper wire bent it &quot;L&quot; shaped and inserted, came out 1 1/2 inches below bend. So mine was definately low. Question is who is responsible for filling with lubricant, American Axle, D-C Plant, Delivering Dealer?

Not the Delivering Dealer, the vehicles are driven before they arrive at the Dealer. Driving without fluid would damage them before a Dealer could PDI. American Axle or D-C Plant? D-C quality control failed in every case. If mine had been shipped after being built instead of sitting for 3 weeks dealer would have had plenty of time for thorough pre-delivery. If it had been delivered immediately after arrival instead of sitting another 3 weeks it would again given dealer more time for pre-delivery.


??? ??? ???

 

Well folks, 5% problems reported or not, a locked rear diff that sheared lug nuts on a wheel is a safety concern! Like he said, Wantabee was lucky he didn't get into a bad crack up. Imagine losing a rear wheel while pulling a 11000# 5er! Sub-contractor or not, DC finally releases the vehicle to the consumer, their responsibility in the end. Bickering between NASA and Thiokol about o-rings didn't erase the fact that 7 people died in the Challenger. Folks, this is a safety problem, plain and simple. If there's no TSB/DSB or recall and someone isn't surfing this forum, how would they know of potential significant problems with their vehicle. I would still at least query TC or DOT about the issue.

 

Seirra:<br><br>You hit the nail right on the head...who is responsible?? Mine went through quality control inspection at the plant and a PDI.....I think all parties concerned need to brush up on their quality control. Don't get me wrong...I love this truck...but you don't expect this kind of a problem with a truck that is 4 days old!! If the checks and balances were followed all parties up the line to the point of delivery...we would in my opinion not be discussing this issue on this post.<br><br>Regards<br><br><br>Wantabee

 

I guess I'm still a little confused about the cause of wantabee's casualty. I thought it was reported that there were no leaks in the diff. Then the dealer reports that the fluid level was correct - I'm thinking that without any leaks it must have been topped off properly when it failed. Diff then siezes, presumably due to a sheared bolt? and not due to a lack of lubrication. Sounds like a possible isolated material problem rather than a quality control or DC/dealer prep issue; or is someone blowing warm air up our skirts? <br><br>I think Phils low level situation brings up the biggest question on who is responsible, and I think it falls under DC's repsonsibility. I would hazard a guess that AA is contracted to deliver axles with fluid included; AA must have a procedure to test the diff's prior to shipment, and I would doubt they would test them dry. And I don't think DC would knowingly permit the guys to drive new vehicles off the assy line w/o oil in all parts of the drive train. I'm sure DC will end up footing the bill, and then having off-line discussions with AA concerning quality control.<br><br>I grew up in Detroit, and every year for a school field trip, we would visit the rouge plant in Dearborn and see the big ore carriers at one end of the plant, walking all the way through and watching guys squealing the tires of brand new cars off the line at the other end of the plant - I always wanted that job.

 

I e-mailed fleet manager at my selling dealer. He thanked me for the info and said he was having his checked. Also, he is alerting their service manager.

Wantabee, how can they say the fluid was at the proper level at the time of the failure. Could someone have added some to cover their backside. It has been done before. If there is no lubricant in the rear axle just imagine how much heat is generated at high speed. It is doubtful they will find evidence of defective parts since high temperature weakens steel and destroys its ability to withstand stress which in turn causes parts failure.

It is hard to conceive of a hub nut failure without fluid leaking out anyway. Maybe they hypothesized that correct fluid level was present since some may have been present after failure. I'm beginning to smell something. Keep us posted.

 

??? ??? ??? ??? ??? ??? ??? ??? ??? ???<br><br>The dealer where my vehicle is located is saying there was sufficient fluid in the rear end when in failed. First there was insufficient...now there is sufficient??? If there was the right amount, why would a bolt which holds the hub on the axle shread?? I fully believe there was no sufficient oil in the differential and it seized. DC has decided to fly me in a complete new differential assembly from Mexico...the old assembly is being sent to engineering for testing..wether oil was added after the fact will able to be determined from a lab analysis and examination of the side axles etc..<br>Canadian Transport safety officials are keenly interetsed in the failure of this unit at low milage...be rest assured...DC will get to the bottom of this and if there was hanky panky committed at the dealers to cover up for a incomplete PDI...it will come out....they are not going to sacrifice the reputation of the '03 Heavy Duties to protect a possible slip up at the contracted supplier or a dealer. I am not comfortable with the explainations given to date...but the long and short of it is they are fixing my truck...and I have involved a goverment safety agency to ensure there are no other possible potential defects which could put the safty of others in question.<br><br>But lets have faith...DC has been very professional in dealing with me on this issue...they were made aware of the problem on the morning of the 8th and at 1630hrs est..a new differential is taken from a unit in Mexico and put on a plane. That is very good service which we should all expect....and in this instance they delivered. I am off that this occured to my vehicle, but my family and I are safe...we could have been in a very serious accident of worse ... I hope the action taken by DC corrects the problem...if there is any vibration in the drivetrain after the differential is put in.....the truck will not be leaving the lot until it is fixed. <br><br>This is unfortunate circumstances...but happens..DC is doing their best in my estimation to get to the bottom of it....I hope they do not let me down [undecided]<br><br><br>Wantabee

 

I just wanted to say that I really like you atitude in this unfortunate situation. I work in a service oriented job dealing with people and dozens of suppliers every day. Too many people think that things are perfect and nothing should ever go wrong with anything. Then they play the &quot;rich &quot; game with you. But any way I hope they get it all fixed up for you, you are a good customer I can tell.

 

Hey guys, I think we should suggest a possible solution to D-C for these rear end lubricant maybe a Gl-5 modifier would help. All they need to be singing again is a little Preparation H.

 

I took mine over last night. 1 1/2 quarts low. Dealer topped it off and everything is ok...

 

Glad to hear your is OK, Wick. Keep in mind that there is a potential for problems to result as a result of under-fill. The drive pinion bearings are the most likely as they are under the most pressure and torque. Noise sneaks up and suddenly it's there. If you hear it under load only, its the rear bearing. If you hear it on coast, its the front bearing. Hope you never hear either.<br><br>Glad you have the documentation as proof if a problem does develop.