Friends, during the second free service (@ 5000 Kms) of my Delta 1.6, I reported a suspension related issue at the Service Center: A heavy clunking sound which apparently originates from the “Rear Axle Tube” only when the vehicle is turning on a path with any gradient. Say, on a Ramp or curved path wherein the vehicle would require bending on one side due to slope in the path. I first heard this sound at around 1000 kms when it was quite faint. It used to sound like a splash of water bouncing inside a tank. So going by the poor sound insulation levels of this vehicle I figured it’s the sound of Diesel splashing inside the fuel tank. Well, this sound kept on increasing and at post 5000 kms, this sound had become pretty audible both on the inside as well as outside of the car. It was quite disturbing to hear it especially on the outside. My SA acknowledged this problem and forwarded the case to MSIL’s technical back-end along with photos of the Axle tube. He told that there was nothing to worry as it was just a sound coming from the axle-tube probably due to defective welding at some joint. Furthermore, he said that no damage is possible to any other suspension part because of this sound.
Over one week had gone by and my SA did not revert. After calling him up, he told that a reply regarding my case was still pending with the technical/quality team of MSIL. Also, he gave a verbal assurance of replacing this faulty Axle Tube under warranty. When asked the reason for so much delay he said that service teams are currently busy with the service re-calls of Baleno & S-Cross due to which my case was being delayed. How could such a reason be even remotely related to my issue?
Upon this delay, I wrote a complaint to NEXA via e-mail and cited the entire case along with many words of disappointment. On the next day itself I got a call from the Regional Head of NEXA assuring closure of this issue asap.
On the next day itself, I received a call from my SA requesting to bring in the Car for 3-4 hours. The solution offered – Swapping my rear axle tube (only) from their 1.6 Alpha TD Car for making an accurate diagnosis. He said after this swap they can be sure about the problem by checking both the cars and order any other prospective parts along with the Axle Tube. I agreed, and took the car to the workshop.
After 3 long hours of personally inspecting the swap it was time for the Road Test. I had my fingers crossed. To our happiness

, no sound was heard during our rigorous road test done mostly on ramps and sharp turns. But at the fag end of it, while entering back into the Service Centre, slight sound (2-3 light clunks) was again heard from the rear right side after descending from the ramp

. My SA seemed as disappointed as me. Afterwards, the SA requested to keep my car at the service center while they would now check the Test Drive Car with my “faulty” axle tube. After about an hour or so I got a call from my SA saying that the Test Car vehicle was facing the same problem with as much sound as observed in my car before the swap. In the late evening, my SA called up to collect my car.
Upon meeting him he told that after discussing the observations with their back-end it was concluded that my car indeed had a faulty axle tube. He told he had punched the order for a new Rear Axle assembly and said it would take around one week for its delivery .Until that time I would be driving my car with the axle tube fitted from their Test Car. Before leaving, even I took the Test Car for a road test and it indeed was having that same problem.
In light of the above scenario, I have a few queries folks:
1. Though MSIL never pointed or mentioned, but my car is fitted with new 16” alloys. I purchased them from the open market after getting a buy-back for the OEM alloys. Are these news alloys responsible for causing any sort of impact on the axle tube in any way? PS : There is no wear and tear to my tyres or shockers due to these alloys.
2. Do any of you face the same problem? If yes, what corrective action did you take?
3. Do you think MSIL is diagnosing the problem correctly?
Note from Support:
- not more than two smilies allowed per post
- proper spacing enhances readability