Really the best you can do is call the company and make a lot of noise complaining about it, and try to get them to reimburse you somehow. Your damages are pretty minimal (at most) and you wouldn't be able to recover enough from a lawsuit to make the lawsuit worth it.
Depending on the nature of your case, you might be able to find an appellate lawyer who is willing to represent you pro bono (for free), in filing your petition for review to the Supreme Court. There are also law schools that have student clinics that might be willing and able to help (again, for free). But it will depend on whether you've got a strong case for appeal.
If the client is not fulfilling obligations under a contract with your employer, then it seems your employer ought to be the one considering a lawsuit against the client -- or at least trying to work out some resolution to the problem. Have you discussed this with your employer?
Do you have representation? If you don't have a lawyer helping you, I recommend you find one. This does sound like an appealable issue. For starters, the ALJ is supposed to notify you of the ME's appearance in the "Remarks" section of the Notice of Hearing. And yes, the ME is supposed to be qualified, and the ALJ should have established the ME's qualifications during the hearing. Without knowing more about your situation, it's hard to say anything for sure -- but you definitely should have a...
If the final order hasn't been signed and entered yet, you should try to get things fixed before that happens. It's easier that way, and the judge will appreciate it more than having his ruling appealed (and reversed). You really should have an attorney helping you -- somebody should be willing to work out a fee arrangement that works for you.
"Judicial activism" supposedly refers to decisions wherein the judge(s) "make" law instead of simply "following" the law. Of course, at the appellate level, many decisions involve "making" new law -- especially at the Supreme Court level, where the case wouldn't get that far if the law was already so clear that it could simply be "followed." Thus, "judicial activism" doesn't really have much meaning in the legal context. It's really more of a political term -- something that one side accuses...
Is this in federal court? If so, there's a motion for rehearing en banc that can be filed, in which you would explain why the 3-judge panel made a mistake and ask the whole court (all judges together) to reconsider. If it's in state court, there's usually a similar mechanism for rehearing/reconsideration, but it depends on the state. The deadlines for such motions are usually short, so you have to move quickly. And the likelihood of success isn't very high. But it's higher than the likelihood...
Many employers value military experience because it signifies a certain level of discipline or a certain skill set. There's nothing wrong with employers having a preference for military vets, just as there's nothing wrong with having a preference for college graduates or for people who have another kind of training. You can't sue over this.
I would caution you against turning over any parts to anyone else. You should find an attorney immediately to discuss your options under Alabama consumer protection laws. It's possible you might have a class action, too, covering anyone who purchased this model, if there was something inherently wrong with the circuit board. If Sears won't make it right for you, get an attorney right away.
If you want to keep it separate from divorce issues, you could try focusing on the MSD itself, if it is your property, and file a suit for conversion (basically a common-law suit for stealing), to try to get your MSD back. But I recommend doing everything you can to settle the matter directly with her, if you can. Litigating should be your last resort in this situation.