I was just looking at my 540's face and I think a hairline crack has developed along the top middle part of the face where it meets the crown. In the picture you can see the "crack" which feels like a little ridge when I run my finger across it. I haven't noticed any distance loss yet but I'd imagine it's just a matter of time before the weld totally breaks, if it's indeed a crack, and the face caves in.

Would anyone know what TaylorMade's policy is on such returns? Is there a guarantee on the welding? And would previously reshafting a club "void" a warranty? Is there a time limit to their warranties?

Ive had several heads crack on me before and my best guess is that TM will send you a new club, I returned an ERC 2 head only to atsugi base that i didn't even buy from them and a month later I got a new head with a new stock shaft in the plastic. Should be no problem let us know if it is.

Judging by the picture would you say it's a cracked head? I'm guessing it would have to go to TaylorMade in the U.S.?

Because it is the Conforming version I think that only TM U.S can help you there. Just drop them an E-mail and ship it to them. It looks like a small crack to me.

Thanks for the help Chris. :D