I had a EGR pipe failure on my 07 KJ CRD in the past week. Heres the link to the post on the subject:

http://www.lostjeeps.com/forum/phpBB3/vie ... hp?t=47896

Here in Australia it has come to light through other forums (like Australian Jeep Offroad) that there have been other instances of EGR Pipe failures. Service centre personnel seem to be checking these pipes as part of routine service. Mine is covered by warranty and there will be no cost "this time". I was wondering if this has been a problem in the US? It seems to mainly affect the 07 KJs in Australia. There is no TSB or Recall on these but I am trying to build a case with Chrysler Australia for something to be done as there just seems to be to many coincidences. Let me know here if you have had similiar problems. I am trying to collect VIN numbers of the affected vehicles so that I can build a case for action. Service advise this is a six hour job to replace these things and that can get very expensive in a post-warranty environment.

EGR gas is kinda hot. Hope nothing else melted. How do you split a steel tube?

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2005 sport crd-SOLD No regrets

Tubing comes in seamed and seamless, seamless costs more and Beancounters only look at the bottom line not quality.
If the seam has a lousy weld, it can split open.
Do an ORM or SEGR and the pipe will not get hot and your problems will cease.

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

I picked up the KJ today after the replacement of the EGR Pipe. The pipe broke at the exhaust manifold end where the flange welded on to the pipe (which is attached to the manifold via a clamp) broke loose at the weld allowing the exhaust pressure to escape and dropping available boost drive at the turbo - it was a crap weld just a couple of thin spots not a strong bead. I now have the 'new' pipe which has improved flange full bead welding according to my service manager. I suggest all CRD owners read the post below outlining the problem and how it was fixed under warranty. As my KJ CRD is one of the last built it is very likely that they all have this problem (the old pipe) - whether they break or not seems to be a matter of luck, the terrain (ie vibration) you drive on and possibility of corrosion. The part numbers are listed in the post but this is not something that you can fix yourself.

http://www.lostjeeps.com/forum/phpBB3/vie ... 924#528924

A 2007 KJ? Over here a 2007 is a KK. Do you mind sharing your build date?

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2005 CRD Limited Flame Red w/ Renegade rock rails & light bar, AirLift 1000. 225/75R16 MT/R's on cheap black steel wheels, dual MOPAR subwoofers, Ipod kit & seat covers, Samco hoses - totaled and gone. 2008 WK Laredo 3.0L diesel - AirLift 1000, wife won't let me mess with it much. 2013 JK Sahara on order.

My KJ has a build date in April 2007, and these were being sold up to the end of 2007. Over here KKs were not introduced until the 2008 model year. Last six of the VIN is 677727. I imagine they were mostly export models being made on the KJ line at that time.

2008 is the KK in the US. KK were sold as MY 08.

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No longer a CRD or Jeep owner. Selling everything I have, needs to go as I need the room for a project.