Locker Position Sensor Potting - DANA 44

[chevymitchell]

Thank you @chevymitchell. I just completed potting my sensors (2018 JLUR with 12,900 miles). There was a small amount of oil in the rear sensor, the front sensor was dry. Thanks to your instructions, everything went well and I have hopefully avoided a future failure.

You’re welcome man. I just did @UNC Rubicon ’s sensors today. Both of his had oil with the rear sensor about half full. Hopefully we can catch a bunch of these before failure. Glad it worked out for you.

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[Ospreyfe55]

Is there any issue with re-using the diff cover bolts? From what I read the torque sheets state that you need to use new bolts on the diffs! If reusing the bolts, do you recommended any type of loctite/ Blue? Red?

 

[chevymitchell]

Is there any issue with re-using the diff cover bolts? From what I read the torque sheets state that you need to use new bolts on the diffs! If reusing the bolts, do you recommended any type of loctite/ Blue? Red?

No issues. You can use some red Loctite on them.

 

[redsyphon]

Well, both sensors are curing now... Hopefully all goes well and no issues after reinstall ?

Both sensors were dry on mine, 2018 w/19k miles.

 

[FinnCustomKnives]

Well I will definitely check out my sensors when we finally pick it up and report back. It really would be interesting if they have in fact solved it as they say, but are still delivering newly manufactured vehicles with said fault potential sensors.

 

[CenTX JPR]

Finally got to this, thanks again for the write up. Had oil in the rear, thoroughly cleaned it out with brake cleaner, then potted. Front was dry but potted it as well. Used red Loctite on the sensor bolt, blue on diff cover bolts. I did not remove the carrier bolt. I did a short test run with them locked, all seems ok.

I was concerned about the drill bit biting and pulling thru too deep, so I used a 3/16 rivet as a depth stop, but afterward I don't think it was necessary. Bit protrudes a little shy of 1/8". Here are my few pics.

 

[TROYXTROY]

Finally got to this, thanks again for the write up. Had oil in the rear, thoroughly cleaned it out with brake cleaner, then potted. Front was dry but potted it as well. Used red Loctite on the sensor bolt, blue on diff cover bolts. I did not remove the carrier bolt. I did a short test run with them locked, all seems ok.

I was concerned about the drill bit biting and pulling thru too deep, so I used a 3/16 rivet as a depth stop, but afterward I don't think it was necessary. Bit protrudes a little shy of 1/8". Here are my few pics.

I like the rivet idea! Thanks for the info....

 

[chevymitchell]

Finally got to this, thanks again for the write up. Had oil in the rear, thoroughly cleaned it out with brake cleaner, then potted. Front was dry but potted it as well. Used red Loctite on the sensor bolt, blue on diff cover bolts. I did not remove the carrier bolt. I did a short test run with them locked, all seems ok.

I was concerned about the drill bit biting and pulling thru too deep, so I used a 3/16 rivet as a depth stop, but afterward I don't think it was necessary. Bit protrudes a little shy of 1/8". Here are my few pics.

No worries at all. I'm glad you got around to doing it before it failed.

I must caution against brake cleaner and electronic components though. Brake Cleaner will essentially ruin any solder runs on exposed PCB's. You must use contact cleaner.

Using the rivet as a drill stop is a good idea. Definitely will prevent hitting the pcb like this.

 

[CenTX JPR]

Thanks, guess I should have known that. I did thoroughly blow them dry, and I hope it fully evaporated before any damage. My thinking is this will get me by until a sensor is available in the future (if mine fails).

 

[jabtyler]

I think they put the blinker fluid in the wrong place!?

 

[ZombieHunterAdventures]

Any reason why it seems to happen more often to the rear as opposed to the front sensor?

 

[RubiconToad]

Mine. Rear with oil in it. Thank you for the write up on this issue.

 

[RubiconToad]

Any reason why it seems to happen more often to the rear as opposed to the front sensor?

I assume it’s due to the rear diff seeing highway speeds much more often than the front, keeping the sensor covered in gear lube for extended periods.

 

[DanW]

It is truly mind boggling that they don't have a simple replacement for these sensors. It would save them just an incredible amount of money and hassle. Plus, it is just a big waste of perfectly good axles and a lot of steel.

 

[CarbonSteel]

It is truly mind boggling that they don't have a simple replacement for these sensors. It would save them just an incredible amount of money and hassle. Plus, it is just a big waste of perfectly good axles and a lot of steel.

Smells like a class action lawsuit in the making for those who have a failed sensor out of warranty.

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