Join Date: Mar 2005
Location: Valley Mills, Tx
I had the same problem with mine, and tech support did not provide much help.
Just before I removed it, I sent an email inquiry about this problem but after a few days of no response I decided to just remove it and do something else.
About 3 days after I pulled it, I recieved a call from a regional marketing rep and he said that he thought that he had found an answer. This does not happen on all jeeps but seemed to be more prevalent in the newer ones. He said that jeep had started machining a flat spot on the end of the crosspin on some models and he felt like that was my problem.
Since I had already removed it and sent on down the road via ebay, I did not pursue this any further but I am pretty sure that I remember a flat spot on one of my crosspins, but since I had both the front and rear diffs opened up within about one months time I could not be sure that it was the front one.
That may be why you see some of the other lunchbox locker vendors providing or at least recommending a new crosspin.
I don't know if this is on the right track or not, but it made more sense to me than any other explanations I had seen. If you look at detail pics of any of the lunchbox lockers you will notice that the are all virtually the same unit with just slight differences in pin/spring configuration.
05 Grand Cherokee Limited, 5.7 hemi, quadradrive II, Nav, 3" lift, JK Rubi wheels/tires, 4xGuard skids