Locker Position Sensor Potting - DANA 44

[Ospreyfe55]

If I get a new, third rear axle from warranty coverage I will def be doing this

Wow that is crazy! I will say the toughest part of this job is waiting on the compound to dry before reinstalling the sensors. But to me not having to deal with axle replacements and the service department is so worth the work. Now I just need to get some gear oil.

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[Shaffer9]

I just potted my sensors this weekend with good results so far. If you put a drill stop in place (I used the rivet method from this thread) then you will have no worries while drilling. I actually held mine in my hand and used a cordless drill, couldn't have been easier.

 

[WagzDad]

You can Google ELECTRONICS POTTING COMPOUND or ELECTRONICS ENCAPSULATING COMPOUND. You should yield several results doing this.

Just a note to say thank you for your support by creating this process thread.

 

[chevymitchell]

Just a note to say thank you for your support by creating this process thread.

You're very welcome.

 

[nU7OuxIx]

Goofy question. The OP mentioned something about using a sharpie to make a mark on something? What was the mark made on? I can't see anything that has a sharpie mark on it.

Thanks!

 

[chevymitchell]

Goofy question. The OP mentioned something about using a sharpie to make a mark on something? What was the mark made on? I can't see anything that has a sharpie mark on it.

Thanks!

I used a Sharpe to mark the cover with two small black dots. These dots are where I drilled the holes.

 

[Ospreyfe55]

Just finished this on my Gladiator! Process went a lot faster from the 1st time I did this on my JL. What helped a lot was jacking up the front driver side to make it easier to get to the diff cover bolts. I was able to get the sensors out without removing the cap bolts. I haven’t tested the system yet but this was the first thing I did as my Gladiator only has about 460 miles on it! I ended up getting 3 bottles of Amsoil 75w140 and putting it in the F & R axles.

 

[DanW]

Just finished this on my Gladiator! Process went a lot faster from the 1st time I did this on my JL. What helped a lot was jacking up the front driver side to make it easier to get to the diff cover bolts. I was able to get the sensors out without removing the cap bolts. I haven’t tested the system yet but this was the first thing I did as my Gladiator only has about 460 miles on it! I ended up getting 3 bottles of Amsoil 75w140 and putting it in the F & R axles.

How did the sensors look? Did they have oil in them yet?

 

[Ospreyfe55]

How did the sensors look? Did they have oil in them yet?

Nope they were dry. Then again the Gladiator only has a few hundred miles on it.

 

[DanW]

Nope they were dry. Then again the Gladiator only has a few hundred miles on it.

Well, that's still good. I've got 47k on mine and am getting ready to re-gear with 4.56 rings/pinions, so I'm going to pot them when the guy has the diffs apart, if they show oil intrusion. If they don't, then I may not bother with them. It'll be interesting to see what's going on in there.

 

[Ridgway Jeeper]

I pulled mine today and potted them. Pretty easy really, the drilling is not much to worry about. I used a cordless variable speed drill and went slow. Wasn't a big deal. No oil intrusion in either of mine yet

There were some fines on both plugs, front fluid was still really clear. The Jeep has about 1900 miles on it with three trail days in 4wd and some locker use. The worst part is the thread locker on the diff cover bolts. Makes them hard to turn the whole way out and the one I had to do with a hand wrench on the front tested my patience. They are on the bench drying now, going back in in the morning.

I am using Amsoil severe gear 75-90. This is my wifes car and will never tow anything.

 

[Newbalewb]

I’m guessing this is still common on new Jeeps?

 

[Ospreyfe55]

I’m guessing this is still common on new Jeeps?

Yep! Unfortunately Jeep hasn’t addressed the issue and leaves customers to fight warranty and replace axles instead of having their vendor pot them! Even if they release the sensor to be sold individually it would still need to be potted so it doesn’t fail!

 

[JAF1]

Just did this procedure over the weekend. I only had 5k miles and there were no signs of oil in either sensor. I used a drill bit stop and a old weak drill to make sure I kept the speed down. I ended up using Orange threadlocker on that bolt...just in case I ever really need to remove it. Thanks to @chevymitchell and everyone else for procedure and tips. Hopefully this is just one less thing to ever need to worry about.

 

[BadA$$Rubi]

I potted my sensors on my JL at 800 miles and saw no evidence that Jeep has ever addressed the issue with oil getting in the sensors. I just ordered a new tube of compound that I will do the same on my new Gladiator and currently have less than 400 miles on it. I will say after I potted my sensors the lockers took less time to engage/disengage. I have heard to many stories of people being outside of warranty or regeared and had to have their axles replaced due to a failed sensor. I was nervous about doing this at first but took my time and learned a lot about this process before I tackled it. Just go slow when drilling but it’s really not that bad of a job.

A drill press works better than a hand held drill IMO.

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