I think (read as "hope") we have some progress. Here's what I've done:
- I have ordered the transmission adaptor plug. It's arrived and I've shelved it for now... just in case.
- I found where to buy a replacement plug & lead for the transfer case position sensor. See my post in the "Everything CRD" thread for details. I replaced the lead, but the problem persisted.
- Getting suspicious of the new transfer case position sensor itself, I soldered/heat shrunk a 390ohm and 22ohm resistor in series (to make as close as I could to 410ohm). I unplugged the transfer case position sensor and inserted the resistors, taped it all up and went for a test drive. No fault - a clue.
- Fortunately, I kept the old switch. I've given it a really good clean and re-installed it. So far, no fault.
It would seem I bought a dodgy transfer case position sensor. Surprising, because it was a Dorman purchased from a popular USA on-line shop, one that I would have expected to be "rock" solid.
It's probably going to cost more in freight that it's worth to return it.
I have a genuine Mopar one on order. Fingers crossed.