We finally blew up the front diff finally. Blew a perfect size hole out the bottom of the housing, and when we opened it up we found teeth everywhere. Also missing a correction pin or whatever it is called that sits between the spider gears. We dropped it off at the dealership after stuffing the hole and driving the last mile there. We are looking for any advice or even help on the issuse it the dealer does not cover it.

How many KJ's crd and gasser have blown there front diff up also?

Just a couple of thoughts.

Maybe the "general" section would be a better place because it's not just a CRD problem.

Second, don't count on dealer help and you'll not be dissapointed. It will not be "can not duplicate" it will be "owner abuse" You took the jeep off road That "Trail Rated" is just a badge that I think covers the hole where the side marker lights go overseas. Even though it seems to be more then a isolated instance.

I could be all wrong, just my 2 cents.

EDIT: Here's one on ebay for $400
http://tinyurl.com/lqbetl

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

Since the CRD makes up for a very small percentage (in the US) of the total KJs on the road I'd say very few CRDs specifically had this issue. The failure is not necessarily CRD specific so you might get more insight in the general 4x4 section.

Front diff failure is something that's always on my mind when I'm offroad mostly since it's my only ride. In (my) theory, ESP should make it more difficult to blow up the front diff due to the braking action and throttle control but there have been one or two folks who have tried hard enough to make it 'splode anyway. I also believe that my DTT helps with the survivability.

If you have to go out of pocket to replace the diff, I think tkkj2002 has his original front diff but I'm not sure if he's selling it; although it would be completely useless to him at this point. If you were going to do it and you have the means, might as well do the re-gear, DTT and locker.

Overall, there are probably less than 10 active LOST members that have had this failure.

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2006 CRD http://www.UtahPowderCoatings.com/ http://www.gorecon.com/ I'm kind of a big deal.
RL rear bumper, ARB front bumper, Mile Marker winch, Power Tank, Skids by Mopar & Skid Row, RL Super Skink Sliders, 235/85R16 MTR, Air Flow Snorkel, DTT, 4.10 gears, Frankenlift II, Katskin leather, JL Audio stereo, Rosen video.

Where did you grenade it at (trail)? Pics of the diff? Which dealer? No warranty but you can definitely make them do some ooh's and ahhh's. I like the former Lithia Dealer (now Colorado Chrysler/Jeep) on Havana.

By the way, what brought you to Buckley the other day?

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New KJ Gear - Desert Armor Flak

2004 Renegade Light Khaki - 4" JBA Lift - Rock Lizard Products: Komodo Dragon Rear Bumper, Prototype Winch-mount Front Bumper, Super Skink Sliders - All J's Super Tranny Skid II - 31" Firestone Destination AT's on Moab wheels - Cobra 75W CB w/ stock Antenna mod

[b]Retired, US Military

Ok thanks everyone for the help. I am hoping i can get my dealer to warranty it for my girl, since they have warranted worst for my TJ. Also i understand that since it was off road that they might not also.

Umm, well we had the diff break on us on the highway coming back from a trail. It was not hard, and the girl never put a lot of strain on the diff either.

Pic's well when i go to the dealer tommorrow morning i well get some pic's of it. There was teeth everywhere and a small pen sized hole from it shooting the spider pin out of the diff.
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Oh i was up at the base doing some payments and getting some things for my 3 week school i am going to .