The biggest issue you will need to overcome is the vin mismatch problem. this will not allow the jeep to start or pass inspection due to the fact that the vin of the jeep body no longer matching some of the electronics. And you will not have any working gauges either and you need to find a way...
I have the 40 series original muffler and its barely street legal due to the sound, but my jeep is the fun joy ride and show jeep now. Next I may even completely remove the muffler or go with a super 10 series muffler.
If you want to swap out the Powertrain Control Module, then you also need to swap in The Body Control Module and also every computer that has the VIN programmed into it or the jeep will never start.
Welcome! All you need from the 2005 is the engine and then you need to swap a few parts from the 2002 engine to the 2005 engine including all the electrical sensors.
First thing I would is to have new u joints put in the rear driveshaft and have it balanced as well as an inspection of the front driveshaft to make sure none of the boots are torn. As for rebuilding the transfer case you would be better off going to a junk yard and buying another one for around...
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