Neutral safety switch on my 01 xj will not come off. I have tried everything possible and it won't move a millimeter. Pb blaster and pry bars do nothing. Anyone have suggestions on how to get it off? Putting the nut on a little to try to pry it off doesn't work.

 

Years ago a guy made a 3D printed tool for this.
I saved the file and had my neighbor print one up for me just incase.
Have yet to use it but it supposed to make removal easier.

https://www.thingiverse.com/thing:3372556

 

Heat is your best bet. Use a propane or MAP gas torch to carefully heat the switch's aluminum body. It will expand and break the corrosion seal. Then try to turn it. Don't worry about hurting it, you're replacing it anyway. Just avoid roasting the wiring harness.

 

Just remember, tightening the nut, compresses the barrel of the NSS on the shaft. Take the nut and washer off completely. Use a small pick to clean out any debris in the slots. Clean the shaft too. Flush out with brake clean. Douse with penetrant. Apply more heat.

Are you replacing it or attempting to repair it?

 

The back of it is plastic, so be careful prying or using heat. There's also a seal in the trans you can melt. The threaded portion is aluminum and you will break the prongs off if you pry on the nut. You can try taping it inward first to break things loose.

If you get it off intact, it's easy enough to refurbish instead of paying $140 for a new one.

 

It will expand and break the corrosion seal. Then try to turn it. Don't worry about hurting it, you're replacing it anyway. Just avoid roasting the wiring harness.

 

My point was that if you get it off intact, it's pretty easy to refurbish the old one. The cheapest I've seen new ones for a 1997-2001 is $53.