Thought I'd give an update on this thread. The car now has 180,000km on the clock and to say this year has been a challenge wrt to the KJ is a serious understatement. Since end of last year we've sunk some serious money and time into it. Had I known back then this would be the case we most likely would have sold it and used the sale money plus the money outlaid to buy something else. I think we've replaced half of the car from the front bumper to the tow ball so really there's no choice now but to keep it for the long haul. As long as it gives us a break from both financial and emotional grief for a while I'll be happy.
So what's been done? List is below and if/when I dig out more definite costs I'll put them up.
Alternator - changed end of last year after the clutch pulley called it quits. Found the aftermarket unit at a place in Eagle Farm Brisbane called "Cool....." something.
Bit under $500 from memory.
New timing belt/tensioner/pulleys plus water pump plus serpentine belt - done just before Christmas. Cost a total of around $3500. I did get a water pump from VM in the UK but they sent the wrong one so I still had to buy local. On top of that it literally took until earlier this week to get a refund from VM and I really had to hound them for this. It also cost me close to $100 to send the damn thing back to them.
New rockers/lifters/head gasket/glow plugs - After the car crapped itself mid February (cause not determined definitely) the same mechanic who did the timing belt etc pulled it to bits quite possibly unnecessarily. I then had to get a new head gasket etc and this was a painfully slow process with bits coming snail pace from the UK (still apparently their quickest delivery system!). Paid out a grand for parts but the problem wasn't fixed. Cost more time and stress than anything after agreeing with mechanic to take car elsewhere and no payment required.
New injectors/radiator/heater T hose - After removing the car from the first mechanic it was taken down to Hammonds who did the timing belt around 5 years ago, should have gone there first up. The radiator proved costly as no CRD aftermarket was available so around $900 supply for that alone. All up close to $4500. Only around $900 of total cost was labor.
New hydraulic clutch line - Ended up doing this myself after getting a new unit through Jeeepart in Hervey Bay for $550 delivered. I'm now an expert installing this thing.
New driveshaft front CV joint plus reconditioned diff including all seals and bearings plus new rear wheel bearings - What I thought was the clutch throw out bearing was the driveshaft CV. Having this and the diff done has eliminated most noise coming from under the car and it feels solid. $1765.
New Clutch and throw out bearing plus engine rear oil seal - Have purchased this on suspicion that it will need doing one day as it's the original clutch still and there's a decent oil leak going on. Not installed as yet. Cost around $600 I think.
You could also add the fuel filter head done middle of last year for around $180.
So all up over $12,000 outlaid on this thing in the last 8 months and off the road for around half of that. What have I learned? Stick to a known Jeep mechanic for those jobs you can't do, it will save you grief later. Also make sure you have all parts available before you schedule any work. We all know how expensive these things are to get through the Chrysler dealers and you need to allow time if getting them through them or other sources. After my experiences I'd say get your parts through a local non-dealer supplier so you don't have issues with incorrect part supplies and expensive returns.
So jobs to do still that are on the radar are the clutch and the rust bubbles. Give me a few months at least please before I need to do anything else.
