Gunmen of the Apocalypse - S6-E3
Revealing mistake: At the start of the episode, we see Lister in black and white talking to Loretta. Then we cut back to what's really happening, he is playing on the AR console. Look at the door behind him, you can see Kryten's hand sticking out in the doorway. He is supposed to rush in and start talking, but you can see him waiting off camera to be told when to enter the room.
Trivia: "Meltdown" was originally planned to be the first episode of Series IV of Red Dwarf. However, the militaristic tone of this episode - and in particular Dave Lister's strident anti-war speech near The End of the episode - meant it fell foul of the BBC censors. The original planned transmission date (Feb 14 1991) coincided with the outbreak of "Operation Desert Storm" - the Gulf War...and the BBC felt that an "anti-war" episode of Red Dwarf would be inappropriate for a country at war with Iraq.
Chosen answer: In-universe, after leaving Red Dwarf after his first appearance, Kryten managed to crash Lister's space-bike into an asteroid. Lister found his remains and decided to rebuild him, however, due to the high level of damage and Lister's questionable repair skills, he was unable to recreate Kryten exactly, leading to changes in appearance, personality and accent. In reality, the original actor wasn't available, coupled with presumably practical concerns about one-off makeup as opposed to makeup for a regular cast member, so some visual changes were made.
Tailkinker ★