Perhaps a friend with a portable oxy/acetylene setup could get it hot enough.
Dont neglect the old warm bolt melted crayon trick. Press a crayon on the warm threads and let it penetrate. Gets in where even pb blaster fears to tread.
Follow the video that has you working from below and drop the intermediate shaft from the transfer case to the front punkin.
It is a pretty straight-forward process from there. The started does need a bit of turning in hand to get it aligned to drop down. I had some problems getting that...
Fuel pump.
Next time it does this, cycle the key on and off a few times before trying to restart. This process will build fuel pressure.
You could also check the fuel pressure with a gage.
Consider shopping that part number at a Napa Auto Parts near you. They can likely match a connector and pins in their Belkin line of auto electrical. I got some great OEM style plugs for some GM applications that I could not source at a reasonable price. Napa had it overnite, good pricing...
https://store.mopar.com/oem-parts/mopar-transfer-case-switch-5083138aa?c=Zz1lbGVjdHJpY2FsJnM9c3dpdGNoZXMmbD0xJm49U2VhcmNoIFJlc3VsdHMmYT1qZWVwJm89bGliZXJ0eSZ5PTIwMDYmdD1saW1pdGVkJmU9My03bC12Ni1nYXM%3D
THe number matches the mopar website. Should be a fit -
Cautions - make sure it comes with...
Proper multifunction switch, a relay or 2, and something about enabling in the bcm, if I remember correctly.
See this thread :
Thread 'HOW TO: How to install Mopar Foglights'
https://www.jeepkj.com/threads/how-to-how-to-install-mopar-foglights.26556/
Here is the transfer case switch -
Thread 'Transfer Case Position Switch'
https://www.jeepkj.com/threads/transfer-case-position-switch.76993/
Btw - google has a great search if you just add site:jeepkj.com to the terms you want - much better than the built in one here.
Tailgate:
Thread ''05...
I read both posts - not much experience from me on CRD jeeps, but …
It *now* sounds like you stripped the bolt that holds the pulley to the tensioner bracket.
Why not pull the tensioner out of the jeep and see if you can repair the mounting hole with a threaded insert ? They used to be called...
There is nothing on the dash when you are in 2wd. The lamp shows when the transfer case is in other than 2wd. My 06 is a bit different that my 04. But I do think that 04 shows “part-time” when in 4Hi
Caliper binding / or not re-installed correctly
Pinched brake line / hose
Brake line in the frame damaged when you were doing UCA’s (on the KJ - that funky captive nut with a flag to keep in place can and will clip the brake line if it gets away from you. Not sure on KK - never saw one up close...
So, what you took off is the OEM style. The 660545 picture is a new version - what is important is the white nylon clip. It should look the same (more or less) as to what you took off.
When these break one of a few things happen :
1 - motor locks up - rare
2 - cable binds in the track and...
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