HELP!! Carli lower issues

[AlaskanCummins]

Anyone out there install their Carli lower ball joints yet?



Here's my issue: Just came in from my man cave ****** off. Installed lowers exactyly per instructions, torqued exactly as manual states and the grease zirk fittings will hit the u-joint yolk if turned 80-100* right or left.



If I turn the right knuckle to the left, the right yolk hits the zirk BAD. #@$%!



Same for drivers side - to the right, it hits the zirk BAD. #@$%!



What the H. E. double toothpicks do I have going on here?



They don't hit when both knuckles are in the foward, driving straight and I'll never turn another corner again mode!!! #@$%!

 

[AlaskanCummins]

Here is a picture.

 

[jdbecker2]

That zerk looks a lot different than what's on their website



Lower Ball Joint- Carli

 

[AlaskanCummins]

Well, I'd bet that because this is a first run of these that I got a set that wasn't suppose to go out. This is my armchair quarterback rational that is suppose to make me feel better .



I can't imagine with all the R&D that these guys did that they wouldn't see this.



Calling them first thing in the AM.

 

[DanielMartin]

I put the uppers and lowers on my truck 3 weeks ago. As soon as i got them in headed for CA from Texas and they broke off on the way. The day after i got to Ca i got a call from Carli. I guess the zirks are like just 1/16th to long. I replaced them on my own.

 

[SierraRam]

The pictures at carli show them recessed.



#ad

 

[AlaskanCummins]

Trust me, they're not like in the pics on Carli's web site.



Daniel - how did you get the old threads out of the joint? I attempted to tighten one to see if that'd help and it broke off. So, I removed it. This was the drivers side.



The instructions said in huge, bold letters and exclamation points: Do not modify the zerks... . " and so on.



So, I decided to remove the passenger side and the miserable zerk broke off during removal #@$%!.



This has NOT been a good day.

 

[AlaskanCummins]

Here are the instructions.



I'm not going to do anything but have them send me the correct set, tomorrow UPS RED on their dime.



This in my humble opinion is way UNACCEPTABLE. All that R&D, $450 and this? I'm more than upset.

 

[DanielMartin]

I used a easyout.

 

[pullya]

Please let us know how it works out.

Jay

 

[BigRedRam]

Had my uppers and lowers installed by Carli about 2 weeks ago. May have been one of the first production sets installed. Sage had the same problem and quickly realized that the supplier for the zirk fitting sent him zirks with an increased length of 0. 10 inches. The joints themselves are perfect in every way. Unfortunately a supplier screwed up with a part that was longer than Carlis specification. Arguably it could be said that Carli screwed up and sent the wrong zirk fittings and it would be true. But at the same time he was under major pressure to ship the joints by us, his customers. Having been there the day it was discovered, I can tell you how upset Sage was and the work he was doing to get the correct zirks to his vendors and direct customers ASAP. At this point I would be surprised if any of the incorrect zirks have not been replaced, you could have the new ones in your mail box as we speak. Any one that has worked on new product design, testing and product release will realize how easily this could happen. Problems will periodically happen with anything, the response to correct a problem and stand behind it far outweigh the inconvenience caused.

 

[AMcCormick]

That seems like a pretty tight tolerance? Could you remove the zirk and replace with a "cap". Would have to swap cap to grease. Seems like if it is this tight something could get in there?

 

[AlaskanCummins]

BigRed you have some valid points, and I agree to a certain extent.



However, upon finding out that there eas an issue with these incorrect zerks, each and every box should have been opened up and parts inspected PRIOR to any of them going out. They know who their vendors are and know how many sets went out. I understand the pressure to get their product out to us but it's not an excuse to have less than 100% quality assurance.



Plus, mine was purchased through KLM Performance (awesome service by the way) on the east coast and shipped DIRECTLY from Carli on the west coast because I live in AK and KLM wanted to save me as much as possible in shipping.



AMcCormick - I made the wrong decision in trying to tighten the zerk - It clearly states in the instructions NOT to tamper with the ball joint in ANY way. Best thing to do is just call them directly and handle it that way.



UPDATE -UPDATE -UPDATE



While writing this, I called Carli - they're going to make it right by sending me a new set; overnight shipping. So far, excellent customer service.

 

[AMcCormick]

I just got home and found my new to me Carli minipacks at the front door. Saving up now for the whole front end package and at some point a freespin kit.

 

[AWise]

Not to take this slightly off topic, but for those that have installed the Carli upper and lower BJs and have some miles on them, how are they holding up? Have you had them off road? I have read where some of the cheaper ones will wear out after only a few hours off the pavement. Just curious.

 

[brods]

AC, does making it right mean giving you the product that was pictured on their website, the one with the far superior design of having the zerk in a recessed pocket, the one which you paid top dollar for?


BigRed, since when did bait and switch become a manufacturing defect or supplier mistake? The website still shows pictures of the lower ball joint with the zerk in a recess, which is far less likely to get damaged compared to the zerk on a stick. Are they planning to make the joints with the recess or not? If not they should change the pictures to represent the product people will actually get. Will they warranty the ball joint every time the zerk on a stick breaks off? Do they reimburse for labor to change them out?

It is a shame since the lower ball joint in the Carli website picture is a work of art. Putting the zerk on a stick on that joint is like putting a kmart watch band on a rolex.

 

[AlaskanCummins]

AWise - I've had the upper Carli's since Sept. 2008 - they're like brand new still. My truck doesn't see any "offroad" per se, but the frost heaves on our highways here in Alaska can beat the dog out of the front end.



brods - All I can say is that they sent out a new set of lowers with the correct zerk in them, UPS Red. I should have them tomorrow afternoon. I do all my own work and didn't consider my time for labor, but I did have to move my work schedule around since my truck is down till tomorrow night.



They're covering the warranty fully with both of my zerks being broken off. Now, I suppose I could have used an ez-out, went around town hunting down grease zerks today but I don't believe that should be my responsibility.



So far, I have to give Carli two thumbs up for correcting this oversight that, IMHO shouldn't have happened to begin with. Would I suggest to my friends with Dodge Diesels to purchase them? Absolutely!

 

[BigRedRam]

BigRed you have some valid points, and I agree to a certain extent.



However, upon finding out that there eas an issue with these incorrect zerks, each and every box should have been opened up and parts inspected PRIOR to any of them going out. [/B]

I totally agree, however the first production run was only 25 sets of lowers. Sage saved me one to be installed later in the week and discovered the problem during installation. The other 24 sets had already left his shop. I can only speak from experience. This is the same man who recommended I not install a starter kit until my BFG 315/70/17 were replaced due to a high probability of wobble problems. I can only say good things about the business and the man.

 

[seafish]

OK guys, I am curious about this as eventually I would like to get a set of Carli Upper and Lower BJ to replace my oem which are on the way out.

Can anyone clearly tell me weather the production Carli lowers have a recess where the zerk screws in or not??

I can understand small supplier mistakes leading to big problems, but I also think that the recessed fitting is most likely an improved design, PARTICULARLY since the clearances are so close. I mean, if a zerk that is 1/10" inch longer (barely over 1/8") is actually HITTING the knuckle, then even with the shorter zerk, you are still only talking 1/8" clearance, which given the movement in the suspension of our trucks, and even modern casting tolerances, is still much too close in my mind.

I am NOT at all trying to bash Carli... they clearly make excellent products, and I do not think that they would bother with a bait and switch tactic, but IF the production run does NOT have the recess, and their catalog shows a prototype that still has the recess, then they clearly should correct the catalog image immediately.
It certainly shows that they are an excellent company if they are sending out full repalcement BJ's for broken zerks, but I would still like to know if there is a recess for the zerk, or not.

Alaska Cummins, maybe you can reply when you get the new ones???

TIA

 

[thashane]

I am also interested in this topic. Am currently shopping for BJ's as we speak...