Well after 2 weeks of not hearing back from the dealership concerning my noise in the driveline from 47-51 mph, they finally go back to me today. The "Jeep Specialist" informed the service manager that there is nothing that can be done about it. It is said to be a inherant design flaw with the entire KJ and KK line up. I was told to put one size bigger or smaller than stock tires on it to help alleviate the problem but it will never go away. This is after the dealership has changed out the front exhaust y-pipe, right front cv, checked balance on all tires, serpentine belt tensioner, torque converter and trans flash. I also explained to him that a friend of mine lent me his sound locating muffs with sensors. It is a tool that has 8 sensors with wire leads that get clipped to various components and you drive the vehicle while listening with sound muffs on. Then stopping and moving the sensors to pin point where the noise is coming from until the noise is narrowed down to a location. It has been narrowed down to the rear differential for sure, no doubt about it. They refuse to do anything more about it because he said they probably wont be able to get reimbursed for the repairs made to it thus far.
So it must be my problem them wonderful ASE Chrysler certified techs can't find their precious FSM for a quick refference guide.
The joy of dealerships

Don't make me start again about that .That tool you are referring to is a electronic ear,not real cheap and not a shop tool so they are rare in any shop(though I have one).

Some gear sets just make noise,no way around it(ever heard of GenuWhine gears?) no matter what you do.It could also be the axle housing is slightly bent,just enough to make the gears make noise.It would take alot of time,money,and specialized equipment to determine that.Then again not doing proper maintenance can lead to problems also(which is your problem).Get the rear end rebuilt or find a good used one.

22,200 miles.............really
edit: 22,998 miles

Is your Jeep still under warranty?
If so, then get the number for the Regional Service Advisor..or whatever they call that position now.

If it's still under warranty, they have an obligation to repair it for you.

The reason it wasn't found is most likely due to the inexperience of the techs that were working on it or not having any diagnostic tools that could find a problem.

In my experience at working at GM dealerships, the dealer might have a limit on repair dollars they can spend before they need to get the OK from higher up.

When you contact the Regional, just be polite, tell him/her what problem you have and what you think it could be. He/she will already have all your info, b/c if you ask the dealer for his/her phone number, they will be the first to contact him/her.

If the Regional is any good, you might be given a 'deal' in which they will fix something specific, but after that is done, they won't do anything else. So be careful if you make that deal that you're sure it's the rear end.

Then if you still don't get satisfaction you can always go to arbitration. It might take a while but this is usually the last step in finding a solution.

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Thank you for the advise I was told the Jeep Specialist that I delt with is a regional tech/manager of sorts that deals with Jeep only problems and is the final say in what gets repaired.
I was also told by several folks at the dealer how calm, polite and collected I have been through this entire ordeal.

If I'm not mistaken, I think what Troy was saying was the dealership not fixing the rear end could lead to problems in the future not that because you haven't performed proper maintenance in the past that it has led to this problem.

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Pete
L.O.S.T. #PC050458
'04 Timberland Green Sport w/stuff...
'08 105th Anniversary H-D Dyna Low Rider
OH-58D Kiowa Warrior

Wow when I worked for ford if the rear end needed to be replaced and was under warranty I would have had it in my bay before I got back from the parts counter (somewhat of an exaggeration). I was lucky to work at relatively large dealership near the Maryland warehouse, although we had a pretty big stock. Is it because of the economy or just a Chrysler approval process?

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Fran:2002 Jeep Grand Cherokee Limited 4.7 quadra drive. 31in General Grabber AT2, OME HD, bilstein, IRO sway links, addco rear sway. Kolak 3in cat back flowmaster SUV 50, magnaflow 3in cat, airaid JR kit, ram air, P.I.E. aux adapter, surco 45x50, husky liners.http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=6&t=65276&p=719908#p719908

Mileage be tookied... don't I hear a lot of talk about a lifetime powertrain warranty? At least, my dealership keeps nodding and saying that...
even if the guy you dealt with was the regional muckity muck, he has a supervisor someplace. I'd escalate that... you can't have your machine fall apart under driveline vibrations over this.

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07 Liberty Sport, 245x70r16 Goodyear Silent Armor
02 Wrangler Sahara, 31x10.5r15 Goodyear Silent Armor, ARB Bumper, Patriot Rear Bumper w/tire swing

It is a great dealership to deal with, management anyways. The techs have a lot to be desired, very rude, cocky and low class. Nope no lifetime powertrain warranty, just the standard 3 years 30,00 mile. I do love my KJ but this issue is pushing me ever so closer to the Rubicon. I intend on cruising the lots(not the dealership I have been going to though) this weekend and seeing what is available in my area