New Carli lower issue - check this out!

[AlaskanCummins]

Well fellas, I just drove from Anchorage to Denver and decided to lube my suspension due to this annoying squeak/squeal when I'd turn my wheels at very low speeds (parking lots, etc... )



I narrowed it down to the drivers side ball joint area. I have Carli's both upper and lowers. I greased the uppers and then, on the drivers side, started to put grease in the lower joint.



I got about half a pump, sqeezed a tad bit more and pop - out comes this little jewel from the bottom of the joint.



I don't know if this is detrimental or not. I'm going to get Carli on the phone Monday A. M. and ask.



Second set and it appears as if I'll be getting a third.

 

[BigRedRam]

I’ve got over 5,000 miles on a set of upper and lowers installed in March. They are working perfectly. Think it’s a little early to start another thread of "Carli" problems until you have taken the time to determine what the problem is and had a discussion with Sage. Is the problem a part of the ball joint, Caused by installation ?, or unrelated in the area of the ball joint?

Sage has always taken care of us and arguably makes the best components available for upgrading our trucks. Premature bashing is inappropriate at this point. Just my 2 cents.

 

[AlaskanCummins]

Well Big Red, I believe that starting this thread is very appropriate.



All I'm doing is servicing my ball joint and this comes out of the bottom and you find this acceptable?



I'm sure they'll "take care of me" and want to send me out a new set. Then, I have to take the time to tear down my truck (buy or borrow tools because I'm on the road) and replace them - again.



Installation issue? Are you kidding me?!?!



I'm not bashing anyone and am only providing information from my experiences. I didn't say anything negative at all. Read the post and comprehend the information next time.



No sir, this isn't pre-mature and others out there that are contemplating purchasing these ball joints need to know the problems that arise with them.



I need to clarify that this piece came out from the area where all the allen screws are located - between there and the male part of the joint itself.

 

[BigRedRam]

Well Big Red, I believe that starting this thread is very appropriate.

You are entitled to your opinion. My approach has always been to seek verification of a belief rather than splash a headline suggesting that there are serious ongoing problems with a product or project.



All I'm doing is servicing my ball joint and this comes out of the bottom and you find this acceptable?

I did not indicate that the condition was acceptable. At the same time you did not identify were the material came from. I simply stated that additional information should have been collected prior to the post being made.



I'm sure they'll "take care of me" and want to send me out a new set. Then, I have to take the time to tear down my truck (buy or borrow tools because I'm on the road) and replace them - again.

I did not indicate that Carli will want to send you out a new set, only that regardless of the problem, they have stood behind their products. As far as “again” goes, the only thing wrong was the zirk fittings on you first ball joints.



Installation issue? Are you kidding me?!?!

I concede, you are an excellent mechanic with years of experience. I am not a mechanic and did not install my ball joints. My apologies if I offended you. I am however an Aerospace Engineer who is required to do a variety of things to qualify, verify and test any component that will end up on one of the aircraft that you may occasionally fly on. If one of those parts has a problem, its most typically related to the installation of the part. The determination of whether the problem is with the design of the part, its handling, installation or maintenance is carefully carried out before the manufacturer of the part is blamed.



I'm not bashing anyone and am only providing information from my experiences. I didn't say anything negative at all. Read the post and comprehend the information next time.

Perhapse I don’t understan a negative implication “New Carli lower issue - check this out!”



No sir, this isn't pre-mature and others out there that are contemplating purchasing these ball joints need to know the problems that arise with them. Should you have waited a few days to post your findings? Ask yourself if anything worse than a squeak would have taken place. Didn’t the installation instructions note a special dry lube that would allow the ball to achieve a perfect fit after a few thousand miles?



I need to clarify that this piece came out from the area where all the alien screws are located - between there and the male part of the joint itself.

Is it possible that the photo you posted is a piece of gasket sealing the sections? Is it possible that excessive grease gun pressure could have pushed the gasket out.



But what do I know, I’m not a mechanic.



I will issue my preemptive apologies before you come to California for a visit. My 2 cents

__________________

 

[AlaskanCummins]

Well BigRed, you surly didn't have to be a smart-allec about my mechanic abilities or the lack therof.



This forum isn't for childish behavior. It's for sharing information about products, weather they're good or bad.



I suppose I should have clarified what this piece of metal was that came from the bottom of the joint and I apologize that I didn't. It appears to be, possibly a dust shield or something to that effect. It may possibly be a gasket as you say between the parts.



Once again, I won't know till Monday.

 

[BigRedRam]

Fair enough, I believe we have reached an equitable understanding and am looking forward to your discussion with Sage. You are totally correct that this forum brings to the CTD enthusiast the best information available with enthusiastic debate at times.

 

[DogramTD]

Whew, glad we got that one cleared up! :-{}

 

[TradedV-10foraCummins]

... I'm going to get Carli on the phone Monday A. M. and ask.



Second set and it appears as if I'll be getting a third.

Let us know how it turns out. As someone sitting on the fence about wether or not I want to put $800 plus into ball joints, this is an informative thread to me.



And for my two cents, I didn't see this thread as bashing; especially considering you've already had to redo the ball joints once before. (And judging by the pictures, you most likely will be doing them again. ) I think you have earned the right to express your issues/problems as they occur.

 

[JKreiss]

Thank you Alaskan, i too am about to pull the trigger on these ball joints and am very cautiously waiting. Thank you for all the write-ups, looking forward to the conclusion to this.

 

[carlisuspension]

Hey guys, and Wayne.

The issue that we discovered is hydrogen embrittlement caused during the Zinc process when the baking wasn't done properly.

Hydrogen embrittlement (or hydrogen grooving) is the process by which various metals, most importantly high-strength steel, become brittle and fracture following exposure to hydrogen. Hydrogen embrittlement is often the result of unintentional introduction of hydrogen into susceptible metals during forming or finishing operations. Full definition: Hydrogen embrittlement - Wikipedia, the free encyclopedia

Here's a little bit of our own testing. We took the spindle off of the race truck and grabbed a lower ball joint pin and sunk it with over 700 foot pounds and then beat it with a sledge hammer. The tension on the pin with that much load, if it was brittle, would have popped under that much pressure. We destroyed the spindle and the vice, basically the only things that came out ok were the hammer and the BJ pin.

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We stand behind the product. Wayne has been offered whatever he needs, new product, compensation for his time or installation bills paid and we're sorry that you even have to deal with this, it never should have happened.

We took the entire batch, pulled them out of boxes and went to a third party where each piece was mag'd. It's basically like an x-ray, you charge the part, coat it and then inspect it under UV light where any fractures or cracks from processing will show up. The rest of the batch QC'd and they are shipping. We added that check to the process as well.

I might be a little early here and ruffling some feathers, but information is key in my mind. So the good news is that Sage is aligning the company with a much, much bigger outfit with more machines and more people. We're gaining access to a 5-axis CNC that runs a single program, you put in a block and out comes a competed ball joint piece. You can read more about this on the blog: Dodge Ram Suspension News and Latest Company Updates from Carli Suspension, Inc

We're stepping up the program over here and will continue to make sure that every customer gets what they pay for and is happy with their decision.

Sorry again Wayne and if anyone else has a piece that isn't right, you can expect the same offer. If you guys have any more questions, feel free to PM or email.

 

[JKreiss]

Well... It looks like i'll be ordering mine next week. I'd hate to see what that testing does to my moogs, i know what the California pot holes did

 

[PFranzese]

I haven't ordered anything yet from Carli but I am pretty sure that I will be when I need suspension parts and especially ball joints. The customer service they provide is second to none and should be a model for other companies.



@CarliSuspension: This is probably a stupid question but are all your parts made in the USA with materials also sourced from USA?

 

[AlaskanCummins]

Just getting on computer for update and saw that Carlisuspension already explained it as it was to me earlier today - and much better! Even though I took mental notes!



First and foremost: HUGE 2 THUMBS UP FOR CUSTOMER SERVICE!!!!



Second: Sage is EXTREAMLY upset that this is happening with his product. He also said that he'll do anything to make this right. He's sending out a lower to me where I'm staying in Denver and gave me the choice to have it replaced or do it when I get home.



No matter the choice, he said he'd also compensate me for the time/bill.



I can't say enough about the service or product and would steer anyone who's contemplating purchasing a set to do so.

 

[carlisuspension]

Right on, thank you for the compliment.

Yes, EVERYTHING we build, produce, buy and work with is US MADE. We take a lot of pride in offering a personalized local service, nationwide. Our manufacturers are local (we're also located right in the middle of the desert racing community with a lot of talent close by) and selected based on their performance. Everything from laser cut to sway bar splining to machine parts. Even our machinist comes from a really strong background of producing criticals with a pipeline that consists of roller coaster car connections, Disneyland Monorail, Boeing plane jacks, etc - super high liability and critical part production. We seek out the best and go from there. But to answer your question, yes, it's all bought and built here in the US.

 

[carlisuspension]

Good to hear you're happy Wayne, right on.

 

[Regcabguy]

Carli Suspension products.

Sage is the kind of business owner who does take it home with him. Kind of a rarity these days. He has worked hard and deserves the success his efforts have earned him. Quality guy.

 

[PFranzese]

But to answer your question, yes, it's all bought and built here in the US.

Awesome, I am sick of the "Made in China" tag and the "Designed in USA, Made in China" thing bothers me even more!



I will be ordering suspension parts from Carli when the time comes.

 

[LBARTLETT]

so will they ever be available for us poor 2nd gen guys



I WANT CARLI'S

 

[BigRedRam]

Just getting on computer for update and saw that Carlisuspension already explained it as it was to me earlier today - and much better!

AlaskanCummins, First my apology for bumping heads with you yesterday. Obviously we both have a high regard for Sage, his company and product. Glad you had the guts to say it like you saw it and get the issue promptly resoled using direct communication with Sage. Engineers are known to be anal regarding following procedures that at times may not need to be applied; I have once again proven it to be true.

 

[kscheffler]

another request for 2nd generations ball joints..... please help... .