Document every detail!ninjadroid said:
I had failure to fire and failure to feed problems on my new XD40. The first question Springfield will ask you when you call them is "what brand of ammunition did you use?" So document each failure with the appropriate brand of ammo. And try every brand of ammo you can get.
When you end up sending it back to Springfield for repair you should include a detailed report of the failures. I wish I would have thought to take pictures of my XD failures at the time.
I sent my XD back, had if 'fixed' and it failed again, in a different manner, but it still failed again so I sent it back again. I'm still waiting for it.
Returning a firearm via UPS or FedEx is very expensive ~$60!! Springfield will usually reimburse you for the shipping or give you their shipping account number, either way you will be without your XD for at least two weeks.
Tom