Locker Position Sensor Potting - DANA 44

[HungryHound]

Thanks for the excellent pricedure write-up! Front was almost 1/2 full at 12k miles with no towing. I cheated and used a torx-key set (pics attached) as the shaft is skinny so you don't have to remove the cap bolts.

Only problem I had was a crappy 6-pt Craftsman 10mm socket broke and stripped one of the diff cover bolts. I switched to a thick-walled impact socket after that to break all the cover bolts loose.

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[Ospreyfe55]

I’m sure this won’t get a lot of traction but has anyone typed up a letter and sent it in to FCA in regards to the locker sensor not being available for purchase? I am going to try and type up something and send it to Jeep, Dana and Jeep Cares. I will try to upload it so others can do the same as I see a lot of people on FB not knowing about this issue and several dealers denying warranty repair because of rehears or lifts being install. This is a horrible practice coming from Jeep on this matter!

 

[chevymitchell]

I’m sure this won’t get a lot of traction but has anyone typed up a letter and sent it in to FCA in regards to the locker sensor not being available for purchase? I am going to try and type up something and send it to Jeep, Dana and Jeep Cares. I will try to upload it so others can do the same as I see a lot of people on FB not knowing about this issue and several dealers denying warranty repair because of rehears or lifts being install. This is a horrible practice coming from Jeep on this matter!

FCA is very aware of this issue.

 

[Newbalewb]

Would the 25ml potting compound be enough for 4 axles?

 

[chevymitchell]

Would the 25ml potting compound be enough for 4 axles?

Yeah. That should be plenty.

 

[Siskababa]

For those of you having a little anxiety about drilling too deep and making contact with the pcb, I was too. I used a small round cutting burr appx 1/32" on my dremel, great control and very little pressure needed to make a starter hole. You can then easily increase the hole with burr (or possibly just buy a 3/32" dremel burr?) but I just happened to have a pen vise to fit a 3/32" drill bit to very easily increase the hole size by hand. Mine is a Starrett and a little pricey, but you can find a chinese one on amazon for less than $10
My truck has 35k mi and both sensors had a fair amount of oil in them, and now they are potted. Happy I ran across this thread by chevymitchell while researching about the gear change I'm currently in the middle of. Would have sucked to get it all back together only to have a sensor issues later on.

 

[Tank the Jeep]

For those of you having a little anxiety about drilling too deep and making contact with the pcb,

I touched the circuit board with the drill on both of mine. Whew, no problems.

 

[Caymanedge]

Are you blowing brake cleaner or contact cleaner in prior to potting? Also, everything says three holes yet the pictures only show two. Thx

 

[Ospreyfe55]

Are you blowing brake cleaner or contact cleaner in prior to potting? Also, everything says three holes yet the pictures only show two. Thx

Do not use brake cleaner, only contact cleaner. And there are 3 holes, only 2 on the clear/yellowish cover and the other is in the back of the sensor. There are pictures of this. You will need to make 3 holes or you won’t be able to fill the sensor completely which would defeat the purpose of potting.

 

[Newbalewb]

Are the sensors/axles on the 392 part of this issue as well?

 

[chevymitchell]

Are the sensors/axles on the 392 part of this issue as well?

All of the 210/220 axles use the same locker assembly. Engine size doesn't matter.

 

[chevymitchell]

My sensors are working and I have a Z harness in the glove box. haha, I need a new project so this is now on my to do list. I'm still unsure of the 3rd hole location in the black part of the housing. Once I pull one and review your instructions, I hope the location becomes clear.
It would be great if someone started an an exchange. I'd be happy to pony up $100 for a pair of potted sensors and exchange mine. Thanks for the thread Shawn.

You can ship them to me and I’ll pot them for you and ship them back. Just cover shipping both ways and the material. I know some are uncomfortable with drilling holes in the sensors, but I’ll do it for free. I don’t mind.

 

[BadA$$Rubi]

My sensors are working and I have a Z harness in the glove box. haha, I need a new project so this is now on my to do list. I'm still unsure of the 3rd hole location in the black part of the housing. Once I pull one and review your instructions, I hope the location becomes clear.
It would be great if someone started an an exchange. I'd be happy to pony up $100 for a pair of potted sensors and exchange mine. Thanks for the thread Shawn.

 

[Dyolfknip74]

There are other threads about this. It's covered under Powertrain.

 

[Windshieldfarmer]

Many thanks to the contributors on this board. Successfully potted my sensors yesterday and reinstalled the sensors and new ARB diff covers today. Everything works great. At 16,500 miles and 22 months of ownership there was no leakage yet. My only screwup was I forgot to push the locking tab on the front sensor once I clicked the connector back in place. Given how secure the connector seemed, I don’t think I’m going to open the diff up to check. Probably will at the next diff oil change however.

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