seasons greetings.
G. Voyager, 2.5 crd 52, 88k, 5 speed manual.
I had an increasing grinding or rumbling noise from the front end, which disappeared when turning even slightly left.
at first i thought it was the driveshafts, so changed them, no difference.
So i went to a gearbox specialist, who tested the car and said they thought it was coming from the diff, so i removed the box and took it to them to strip, they went through the whole box and found that a washer type plate or shim within the diff itself was worn and badly scored and had also damaged similarly the seating in the diff.
tried to get the parts from chrysler, who said they are no longer available.
so i got a seconhand box, and fitted it, the exact same problem ? so called the breaker, who sent another immediately, and guess what, exactly the same again ? Now sick and tired of changing boxes.
Is this a really common fault or have i just got the 3 boxes that have it ? is it really the case chrysler cant supply the new parts, or does anyone know different ? I tried to get a diff alone second hand, assuming they maybe plentiful with so many gear jumping problems around, but no joy ! any help appreciated.

 

Hi Johngr,
Just a small idea here that came up a few years ago regarding suspension noises. In this fault a grinding, rubbing noise was coming from front end. Usual worn suspension parts were replaced with no change. Then rubbing marks were noticed on the subframe but drive shaft not touching. On examination engine mounts were found shot, so that when car was powering the drive shaft pulled itself against subframe....Little bugger that one eh.....
Goggs....

 

Thanks Goggs, had a look at that, no evidence if it on mine plus the noise is continual , clutch in or out, accelerating etc.
Have another box coming so will change it again, breaker said they hadn't come across this problem once let alone twice, and in my case 3 times, which really makes me doubt,particularly not seeing it mentioned by anyone else here, so i will split all the diffs to satisfy myself. by the way changed front and rear mounts, drop arm bushes, and drive shafts.
most annoying of all is that Chrysler no longer do the parts, for what was a current box in 2004 !! I thought manufacturers had to keep parts available for ten years ?