I have had an interesting set of events with my 2005 CRD. First I was fighting an overheating problem that turned out to be an uncalibrated (or calibrated for gas) engine temp gauge. High reading on the gauge was 239 dg F so full scale was still in operating range of the CRD. Then I started having high fuel consumption problems. My mileage dropped from about 22 - 27 to around 16 to 18 mpg. Along the way the engine started heating up to higher temps during regular driving (210 to 220). I could see the increase in temp because of my more sensitive temp gauge. Finally I heard a swoosh when I would hit turbo speeds.

No problem, split hose, so new SAMCOs on order and I patched up the split with metal tape and duct tape just in case I needed an emergency vehicle. I test drove the Jeep and now it would not shift into overdrive. I parked the Jeep and waited 5 days for the Samcos to work their way through Fed Ex. I put them on and test drove the Jeep and still it would not shift into overdrive. I did a search on the forum looking for "transmission will not shift into overdrive" and got NADA. I then redid the search on just overdrive and found a forum thread concerning jerky OD operation. The last post said that they had a problem with their CRD not shifting into OD. They tried bleeding the air out of the fuel filter and it worked. Seemed strange to me that air in the fuel would cause a transmission problem but thought that I would try it since it was easy.

I bled my filter, found a little air in it. Under normal circumstances I would not have consider the amount I found a problem, but I thought a test drive is cheap and who knows? It worked. The transmission worked perfectly.

I found each and every one of these problems by searching through the forum; uncalibrated temp gauge on 2005 CRDs from factory; turbo hose splits causing higher operating temperature and lower fuel mileage; and air in fuel filter causing the transmission not to shift into OD.

If there is any good that came out of all of this, my engine finally heated up to 235 dg F so I could verify that the safety system and fan worked properly. They did, I hit first red mark, got 5 chimes and then the fan kicked in, cooling me right back to normal 176.

This post is to thank all of those who posted before me and allowed me to work through this maze of problems on my quirky little Jeep. And to aggregate them in one post so future searchers can find this post tieing all these problems back to a split in a turbo hose.

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Stone White 2005 KJ Limited CRD.
EHS, ORM, Fixed Flex Fan done.
Does EXACTLY what I expected pulling my 20 ft bass boat, chasing reds up and down the beach at North Padre Island.