This place has a good reputation around my area.
https://www.powertrainproducts.net/
It's only about an hour or so away from me.
Would help if you list approximately where you're located. There are people who use this site from all over the world.
When my hg failed in my 02 kj I had a milkshake in the crankcase. I have used a pressure tester to apply pressure to the cooling system and found an "external" hg leak on a Subaru. If you're leaking alot from combustion chamber into coolant you'll know by the boiling coolant. If you're getting...
Check all grounds you can get to and make sure the battery connections are very clean and secure. These things do all sorts of weird stuff with bad electrical connections. The headlights on without taillights sounds almost like a DRL circuit. I guess the timer after shutdown would be similar.
You mentioned harmonic balancer. Did you watch it while running? I had one starting to fail on an 11 avenger and you could see it wobble. They can be tough to see and look OK. The rubber fails but they don't actually get loose at first.
Yeah, probably the outer clutch pulley bearing, but when the clutch engages it changes the amount of stress/force on the whole serpentine system. I have seen it actually quiet other pulleys that were failing so spin all the pulleys while the belt is off.
Did you remove the serpentine belt and spin the outer pulley? If it's just the bearing you should feel it. A clutch replacement would fix this but the bearing itself is replaceable too. That T68184 seems to be a carquest part so seems like there should be a kit or at least a bearing replacement...
The problem would be finding the replacement. I doubt there's much replacement support for that unit. I did the OE clutch in my 05 a while back and it was no big deal. The process is probably the same with the replacement you have but finding that correct clutch is unlikely.
I wouldn't worry too much. Just keep an ear on it and see if it gets louder. Mine eventually became a chain rattle/slap noise after a few years. Mine was over 160k at the time.
My 02 did that clicking. In my case It was the timing chain tensioners pumping up. I changed tensioners and guides while doing an HG replacement and the noise stopped. Lash adjusters can get lazy too. Cold just makes it noticeable. 05 was pretty quiet except for the brief rattle after not...
I think the NSS is in the transmission. Manuals don't have one I think so if auto did you try to start in neutral?
How about the ignition switch? Have you tried jiggling it a bit.
Probably the cable end bushing at the tcase has failed. Check out the linked thread. My 02 took the black rubber bushing 68001899aa but my 05 took the white plastic bushing (B01BX3M514). Both of mine had the 242 tcase with the full and part time 4WD. Not sure what year you have...
I used the Cloyes guides when I did the headgaskets on my 02 many years ago. The one OE guide fell apart when I disassembled for head removal. They did have about 160k on them. The Cloyes guides worked great for me.
First thing to check is the battery (how old is it) and then then the terminal and major ground connections. Disconnecting the battery connections and cleaning well has helped me in the past. These things get real flaky if there is a weak battery of poor power/grounding. Do that first and check...
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