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To defuse the time bomb, best to pot your sensors. I posted a how-to on the topic.

I'm gonna disagree with the others and say your problem is likely not the locker sensor getting contaminated with oil. The fact that the problem shows up during accel/decel says to me that wires are moving around and losing connectivity. There were some other reports of wiring harness issues and...

I just sold these an hour ago.

New gears = more heat = thinner oil + air pressure differentials inside the sensor. It makes sense that a re-gear would accelerate the death of a bad sensor seal. It's no excuse for a bad sensor design, but it explains why a sensor is more likely to fail soon after a re-gear.

They didn't get a new sensor (or solenoid, for that matter). That's still not possible. This is just a game of telephone with a garbled message somewhere between the tech, the service advisor, the customer, and a forum.

Last I checked, the Rubicon differential assembly was not available for purchase outside of a whole axle assembly. Hopefully that's changed since then, but you might want to confirm with your dealer that they've ordered the correct part.

Yup! Pickup location is now in Fremont.

This thread is a how-to for preventing a non-failed sensor from failing. If Jeep/Dana/TE Connectivity got their shit together and made a better sensor then that would be great, but this is a second-best solution.

A while back I was looking at the giant Jeep key fob and thinking about how it could be made smaller. I know about the AJT key fob, but I thought I could make one even smaller and practically for free. Here's what I came up with. Compared to the original fob, it's tiny. It feels much better...

I looked into replacing the hall chip itself, but it's fairly unique. Most hall chips use all three pins, though there are a few that can be used in a 2-wire configuration. Other characteristics that need to match the original sensor are its magnetic flux sense orientation and its actual...

Oil in the connector was the source of my failure, too. I don't think Jeep sealed the middle unused pin on the 3-pin connector, which lets oil into the connector and then the sensor housing. As already mentioned, use contact cleaner to clean it up, then pot your sensors to keep the oil out...

Yup, the two outer pins on the housing connector are connected to the Jeep locker harness. Note that these aren't the two outer pins on the hall chip, though.

Sorry, I don't have the busted sensor any more, but here's a pic of the other side of the PCB. The hole is a mounting hole, which uses a melted plastic boss in lieu of a fastener.

Interesting. Mine was a pain in the butt to open up and it broke in the process. This might mean there are some sensors that leak through the connector while others leak through the lid seam. I pulled a failed sensor completely apart and cleaned it with contact cleaner, but the contamination...

Yes. Or, more accurately, your dash will show it's locked when the signal is sent to lock, regardless whether it's successful or not.

Nope. It assumes the locker is always successful in locking and unlocking. If there's ever a problem, you won't know about it.

You might have a hard time getting the silicone distributed to both sides of the board. Also, popping the lid off is a lot harder than drilling a couple of holes.

Conductive grease seems like it would be a bad idea for a multi-pin connector. My understanding is that as mating contacts slide against one another, the dielectric grease is pushed away from the contact area and the mating contacts have no additional resistance. Usually it's packed into...

It might not be a bad idea to combine that with the internal potting. I know that @wibornz tried the edge-seal method and still ended up getting oil in his new sensor, though, so I think potting will be more effective. I suspect the main entry point is through the connector rather than the...

I wrote up a DIY on potting your sensors to prevent this from happening. https://www.jlwranglerforums.com/fo...s-from-failing-how-to-pot-your-sensors.56892/