Locker Position Sensor Potting - DANA 44

[moeman]

I potted my sensors for $20 but still carry the Z automotive bypass harness in my Jeep.

https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1

Do you have a link for what you’re referring to?

Yes

https://a.co/d/iilR5yQ

When you get it. You'll notice it doesn't fit quite right. If you look inside the connector. You'll see a small plastic tab impeding a perfect fit. What I did is I took a Dremel and a small burr and burred out the plastic tab. And it fit perfectly after that.

I can make a video if you need.

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[Terrymo]

Yes

https://a.co/d/iilR5yQ

When you get it. You'll notice it doesn't fit quite right. If you look inside the connector. You'll see a small plastic tab impeding a perfect fit. What I did is I took a Dremel and a small burr and burred out the plastic tab. And it fit perfectly after that.

I can make a video if you need.

That would be great if you have time.

 

[WannFly]

I used the rivet spacer on my drill bit, had 2mm of bit exposed and this was perfect for drilling through the plastic without going deeper than needed.

Can you put a picture or better yet a link to buy the said contraption. I have everything in the garage to do the work, just need to do it and looking for some kind of drill stop to ensure I dont drill into the PCB.

I do have a few drill stops, but none of them will work from what I can tell on that small sensor

 

[ScottW511]

Can you put a picture or better yet a link to buy the said contraption. I have everything in the garage to do the work, just need to do it and looking for some kind of drill stop to ensure I dont drill into the PCB.

I do have a few drill stops, but none of them will work from what I can tell on that small sensor

Check out post #156. I just copied what cntex jpr did.

 

[THAW]

Jeep should recognize that if the "new locker sensor" is also failing - they should not just sell replacements that will fail just as easily. But instead make sure these will do the job properly for the end user.

https://www.jlwranglerforums.com/forum/threads/locker-sensor-potting-failure.130790/

Did you interpret my thread to mean my new-design sensor failed instead of the intended meaning of me "failing" to pot the sensor (i.e. I didn't need the potting compound I bought before opening the diff and seeing I have the new-design sensor)?

I've seen several forum posts about the new sensor also being prone to failure, but haven't seen any real documentation. I'm wondering if confusion about the meaning of my thread resulted in rumors about new-design sensor failure.

 

[DanW]

You can get the Chinese knockoff for about $25. All you have to do is get a Dremel and burr out the plastic piece in the connector so it can fit

Link? That would be great!

 

[DanW]

Yes

https://a.co/d/iilR5yQ

When you get it. You'll notice it doesn't fit quite right. If you look inside the connector. You'll see a small plastic tab impeding a perfect fit. What I did is I took a Dremel and a small burr and burred out the plastic tab. And it fit perfectly after that.

I can make a video if you need.

Thanks! They are $22. In before the tariffs! LOL!

 

[LukeDagny]

Thanks for the "How To". It looks like my rear sensor has failed, and this thread will be very helpful.

I've only read the first 5-6 pages and the last couple, and not all 64, so this may have been answered already.

Is it possible to purchase an individual sensor without having to buy all 5? Is there a part number for the individual sensor?

 

[Terrymo]

Thanks for the "How To". It looks like my rear sensor has failed, and this thread will be very helpful.

I've only read the first 5-6 pages and the last couple, and not all 64, so this may have been answered already.

Is it possible to purchase an individual sensor without having to buy all 5? Is there a part number for the individual sensor?

You have to buy the set and it’s trial and error which one (ones?) out of the set will work. Even if you found someone to sell them individually it would be a gamble if the one you bought would work for your locker.

I got this educated guess/answer from @roaniecowpony

Terrymo said:
@chevymitchell @roaniecowpony etc
What variables can occur that require all 5 locker position sensors in the kit. I have a hard time believing whoever is originally assembling these axles is hand fitting and swapping the sensors to find out which one works on the rear locker and which one works on the front locker. Seems like there would be something that could be measured by a multimeter to make that decision.

Since a Hall effect generates a small voltage, depending on relative position of the magnet, my guess would be that the mechanical tolerances (variations in dimensions) between the locked and unlocked position of the sensor target (on the actuator plate) relative to the sensor (on the actuator coil) will create different voltages (very small voltage variations) which were probably originally calibrated in the locker module on the production line for the locked and unlocked position. I can't imagine that they are trying different sensors on the production line. They probably just plug in the axle and command the locker on a test console, then burn the voltages for the two positions into the NVM

 

[ym0bc1]

Can't believe I discovered this thread so late! Thank you so much for the write-up.

A few question though:
1. Is this issue only limited to certain model year? Or it still a potential vulnerability in 2025?
2. My Jeep has been running for 35K - is it still worth potting it? Or this should be done when it's new (or that part is new).

 

[LukeDagny]

You have to buy the set and it’s trial and error which one (ones?) out of the set will work. Even if you found someone to sell them individually it would be a gamble if the one you bought would work for your locker.

I got this educated guess/answer from @roaniecowpony

Since a Hall effect generates a small voltage, depending on relative position of the magnet, my guess would be that the mechanical tolerances (variations in dimensions) between the locked and unlocked position of the sensor target (on the actuator plate) relative to the sensor (on the actuator coil) will create different voltages (very small voltage variations) which were probably originally calibrated in the locker module on the production line for the locked and unlocked position. I can't imagine that they are trying different sensors on the production line. They probably just plug in the axle and command the locker on a test console, then burn the voltages for the two positions into the NVM

Terrymo, thanks for the information. It seems MOPAR/DANA eff'ed up on this application.

I still have Chrysler's CPO extended warranty. My deductible is $100. The whole job seems pretty simple, and I was hoping to do it myself for less. I guess I will pay the dealer replace the sensor, and then pot it when I get my Jeep back.

 

[WannFly]

Thanks for the "How To". It looks like my rear sensor has failed, and this thread will be very helpful.

I've only read the first 5-6 pages and the last couple, and not all 64, so this may have been answered already.

Is it possible to purchase an individual sensor without having to buy all 5? Is there a part number for the individual sensor?

I believe you have to buy all 5 and go by trial and error. I did read all the 64 or so pages but can't recall for sure. My memory sucks, so there is that.

 

[BRuby]

Did you interpret my thread to mean my new-design sensor failed instead of the intended meaning of me "failing" to pot the sensor (i.e. I didn't need the potting compound I bought before opening the diff and seeing I have the new-design sensor)?

I've seen several forum posts about the new sensor also being prone to failure, but haven't seen any real documentation. I'm wondering if confusion about the meaning of my thread resulted in rumors about new-design sensor failure.

My comments were based on others posting that the new sensor appears to be prone to failure. Whether this is in fact true is yet to be confirmed by more users. Also notice that I did clearly state “if”.

No worries there was no confusion.

 

[LukeDagny]

I believe you have to buy all 5 and go by trial and error. I did read all the 64 or so pages but can't recall for sure. My memory sucks, so there is that.

Update on my Jeep. Since my Jeep has Mopar's CPO extended warranty, I let the dealer take a look. I was informed my "star case rear differential sensor" is bad. Although my warranty covers axles and axle components, it doesn't cover this sensor. The sensor is considered an electrical component.

They will have to order the sensor for $7.20, and I'm crossing my fingers this price isn't a mistake. The dealership doesn't offer any "loaner" vehicles, so I elected to order the part and do the repair my self. It "only" cost me $133 for diagnostic services for what seems a common part failure not covered by warranty.

 

[swampflyer]

Mine was replaced under warranty by dealer.

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