TFAR

VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

Purpose of TFAR	Approval	Approval / feedback	Warranty	Type of TFAR	Truck Chassis

Subject/Complaint
Abnormal noise coming from 3rd axle differential.
Report Number	691230-1-2023-50822	Report Date	12-Dec-2023	Prepared By	VSPCKORBA
Dealer ID	691230-1	Dealer Name	VSPC-KORBA 1
Customer Name	KALINGA COMMERCIAL CORPORATION	Customer Contact Person	Krupasindhu Mahanta
Workshop/Site-Location	TALAIPALLI RAIGARH	Customer Contact Number	07978296959
Chassis Model with Axle Configuration	FM(4) 460 8x4 BS6	Body CuM & Application	20.3 cum RB HYVA
Chassis No	8-977665	Reg. Number	NA	Date of Delivery	26-Nov-2022
Date of failure	03-Dec-2023	Repair Order No.	13529	Repair Date	05-Dec-2023
Failure Mileage kms	66496	Age in Months	13	Engine Hrs.	6663
Function Group	645	Causal Part No.	60112813	Description	Hex. socket screw
Defect Code Group	3 MALFUNCTION	Defect Code	33-LOOSE
Spare parts warranty	No	Spare parts invoice details		Spare parts fitment date	0000-00-00
Driveline Warranty	Yes	GDR No

Repair Estimate Summary

Material Cost	395829.85	Labor Cost	9844.74	Other Cost	19359.08

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc.	SOIL
Dust Condition (Heavy Slight, etc.,)	SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures	1:16
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.)	SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures	NO

Load Details

Type of load carried	OVER BURDEN	Permitted Technical GCW	49	GCW during failure	47

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc.)
Aggregate	Differential carrier	Aggregate Part No.	22014389	Aggregate Sr. No.	LIN04569991

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name	SHEKH IBRAR AHAMAD.	Training details on the related variant	22/03/2023 To 20/04/2023

Drivers description on the happening of the failure:

Abnormal noise from 3rd axle differential.

Technical Explination of complaint (Dealer comment):

As per DRP we have checked the following point.
* When register the customer complain noise comming from rear side of vehicle during running condition, at first collect
the data through driver interview.
* We start moving the vehicle to confirm the driver complain.
* We noticed grating noise comming from 3rd axle.
* Immediately stop the vehicle on plain surface.
* Then we check the axle oil level and found ok.
* After that we drain the axle oil in a clean container and found meatal particle stuck with drain plug.

Workshop comment: -

After removed 03rd differential and found that due to Diff housing screws (60112813) are loosen and its found in axle casing area. Consequently, damage to 1524856 differential housing & 1524854 differential housing and Spider trust washer scoring mark and diff.cap 1524888) corner damage and diff. housing roller bearing broken- 184623

Fault codes registered in vehicle (Including Active and Inactive Faults)

Is the causal part a recently modified one	no

If Yes, kindly provide more details about the modification:

Is this a repeat failure		Is yes, provide relavant details

Relavant Argus No. If any		Relavant DQR No. If any		Relavant MQR No. If any

Relavant QJ No. If any

Affected Vehicle details

Chassis No	Model	Body No	Date of Delivery	Date of Failure	Mileage Kms	Engine hrs	Parts Sl.no
--	--	--	--	--	--	--	--

Area(Photos Where required/Applicable)

Photo Area	Description/Remarks
	Effected vehicle DPV-509 CH. ID 8-977665
	Vehicle Data
	Differential Hausing with failed metal particle,
	failed metal particle,
	3rd Differential full pic.
	3rd Axle Serial Number Plate
	Complete 3rd diff pic.
	3rd diff. sl no-LIN04569991
	3rd diff. ch id 8-977665
	Hex. socket screw(PN 60112813) open out from differential housing.
	Hex. socket screw(PN 60112813) open out from differential housing.
	Diff. housing spider sitting area damage and Scoring mark found.
	Diff. housing spider sitting area damage and Scoring mark found.
	Diff. housing spider sitting area damage and Scoring mark found.
	Diff. housing spider sitting area damage and Scoring mark found.
	Diff. housing spider sitting area damage and Scoring mark found.
	Spider kit side gear got dip pitting mark found.
	Trust washer condition.
	Trust washer condition.
	Spider got scoring mark found.
	Spider got scoring mark found.
	Diff. housing gear teeth found broken.
	All Hex. socket screw(PN 60112813)
	Bend socket screw.
	Diff. housing roller bearing broken image part no-184623
	Diff. housing roller bearing broken image part no-184623
	Adjusting screw image.
	Adjusting screw 1673663 got damage.
	Thrust washer condition.
	Thrust washer condition.
	Diff. housing cup corner damaged.
	Diff. housing cup corner damaged.
	Diff. housing cup corner damaged.
	Differential carrier housing found ok condition.
	Diff. housing adjusting screw sitting area thread OK.
	Diff. housing adjusting screw sitting area thread OK.
	Diff. housing cap thread ok condition.
	differential gear kit found ok condition.
	Diff. spider found ok.
	Thrust washer condition.
	Thrust washer condition.
	Dog clutch found ok.
	Diff. side gear found ok.
	Needell roller bearing found ok.
	Selector fork found ok.
	Diff. gear found ok.
	Diff. input shaft found ok.
	Sector fork piston and diaphragm seat found ok.

Probable Cause of Failure

Suspect to hexagon screw(60112813) gets Loose due to improper tightening during assy. and consequently damaged to other parts.

Corrective Action/Suggestions

Need replaced failure parts.

Service and Repair History of the vehicle (Relevant to the failure)

S.No.	Job Card No.	Date	Mileage Kms	Engine Hrs.	Job carried out	Remarks
1	DPV-509	17-Apr-2023	30223	2842	Axle oil & Gear oil
2	DPV-509	05-Jun-2023	39031	3768	Basic service	APM Replaced
3	DPV-509	31-Jul-2023	46808	4671	Basic service
4	DPV-509	11-Sep-2023	52469	5267	Axle oil & Gear oil	Return line filter

Repair Estimate

Material Cost

S.No.	Part no	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	1069782	SET SCREW	2	693.47	1,386.94	18	249.65	1,636.59	09
2	20523491	DIFFERENTIAL PINION SET	1	90642.52	90,642.52	28	25,379.91	116,022.43	09
3	1524861	LOCK PLATE	1	1171.14	1,171.14	28	327.92	1,499.06	09
4	1524857	ROLLER BEARING	1	15093.52	15,093.52	18	2,716.83	17,810.35	09
5	1524854	DIFFERENTIAL HOUSING	1	97213.12	97,213.12	28	27,219.67	124,432.79	09
6	60112813	HEX. SOCKET SCREW	12	208.86	2,506.32	18	451.14	2,957.46	09
7	184623	ROLLER BEARING	1	10908.73	10,908.73	18	1,963.57	12,872.30	09
8	1673663	BEARING ADJUSTER	1	5474.56	5,474.56	18	985.42	6,459.98	09
9	181396	ROLLER BEARING	1	32666.24	32,666.24	18	5,879.92	38,546.16	09
10	8171334	NUT	1	4188.58	4,188.58	18	753.94	4,942.52	09
11	914480	RETAINING RING	1	134.4	134.40	18	24.19	158.59	09
12	1524881	NEEDLE BEARING	1	2011	2,011.00	18	361.98	2,372.98	09
13	1524888	CUP	1	15904.36	15,904.36	28	4,453.22	20,357.58	09
14	184622	ROLLER BEARING	1	10396.99	10,396.99	18	1,871.46	12,268.45	09
15	8171338	LOCK NUT	1	3669.27	3,669.27	18	660.47	4,329.74	09
16	21448461	LIP SEAL	1	4418.26	4,418.26	18	795.29	5,213.55	09
17	1524887	THRUST WASHER	4	742.06	2,968.24	18	534.28	3,502.52	09
18	1524988	ROLLER BEARING	2	4357.06	8,714.12	18	1,568.54	10,282.66	09
19	914542	RETAINING RING	1	153.33	153.33	18	27.60	180.93	09
20	1524838	SEALING RING	1	2658.4	2,658.40	18	478.51	3,136.91	09
21	1673393	NUT	1	4058.59	4,058.59	18	730.55	4,789.14	09
22	1069030	OIL COLLECTOR	1	1607.16	1,607.16	28	450.00	2,057.16	09
Total					317,945.79	Total		395,829.86

Labour cost

S.No.	Operation No	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code	Remarks
1	46531-0	Differential carrier, first rear axle, overhaul	10.3	810	8,343.00	18	1,501.74	9,844.74	09
Total					8,343.00	Total		9,844.74

Other cost

S.No.	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code	Remarks
1	OL 1161949 High Perfomance LD Rear Axle Oil	26	631	16,406.00	18	2,953.08	19,359.08	09
Total				16,406.00	Total		19,359.08

Total cost of Repair( Material, Labor and Other cost)	425,033.68

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test		Compulsory for all failures having fault codes
17034-3 Vehicle information test		Compulsory for all failures having fault codes
28486-3 Sensor Values History Report		Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data
28108-8 Engine ECU, check		Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete		Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet		Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint		Compulsary

Additional Attachments

S.No.	Attatchemnt
--	--

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date		Sent to ELF Mumbai

Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No		Dispatch Date		Courier Name		Transporter Veh No.

Present Status of the vehicle

Present Status	Breakdown	Reason	Awaiting for TFAR Approval

Comments

S.No.	Remarks	By	Date & Time	TFAR Status
1	Dear Akin, Above 03rd Differential failure details from KCC-Talaipali Site. C1-Abnormal noise coming from 3rd axle differential. C2- check and found that Differential housing all screws (60112813)are loose and its dislocated from fitment area. C3-need to be replace as per quotation list. Br Workshop Team VSPC Korba	VSPCKORBA	2023-12-12 10:04:28	TFAR RAISED
2	Dear Ayub, Please find the above 3rd Differential failure complaint from KCCL Raigarh Customer site. EATS is not bypassed in this vehicle since DOD. Request you to approve the same to support under in Driveline warranty. C-Abnormal noise coming from 3rd axle differential. C-On observation found that Differential housing all screws (60112813)are loose and its dislocated from fitment area. Consequently damage to other parts. C-Needs to replace parts as per repair estimate	abera	2023-12-12 12:51:09	TFAR FORWARDED
3	Approved to repair under wty IR attached Regards / Ayub	ahussain1	2023-12-13 14:15:28	APPROVED