Locker Position Sensor Potting - DANA 44

[chevymitchell]

Hmm, I just pulled mine apart to do this and it looks like the design changed. 23 Gladiator Mojave.

Yeah. Definitely looks like they went to a sealed hall effect. Much better design, for sure.

Good to see. Thanks for sharing.

Once I get a set of gears in here with this new design, I'll take a much closer look at it.

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[legacy_etu]

Yeah. Definitely looks like they went to a sealed hall effect. Much better design, for sure.

Good to see. Thanks for sharing.

Once I get a set of gears in here with this new design, I'll take a much closer look at it.

Yeah, I was pleasantly surprised. Also freed up my Saturday not needing to sit around waiting for compound to cure., ha!

 

[chevymitchell]

Yeah, I was pleasantly surprised. Also freed up my Saturday not needing to sit around waiting for compound to cure., ha!

That's a bonus!

 

[Aloicious]

Looks like I get to do this on my 21 JLR this weekend, got the rear blinking last week. Ive got the new sensor kit on order as well as the potting epoxy both should arrive tomorrow. Thanks for this great write up!

One question, when testing the 5 sensors in the kit, will incorrect sensors throw a code immediately once installed? Or do you need to drive around with them a little before they'll fail out? Just wondering if I can plug them in while the diff is open, check code while idling and if clear move on to potting right away, or if I really need to close, refill the diff, and drive around a bit for each sensor, or if there is a different procedure for testing the 5 sensors for the proper one.

 

[chevymitchell]

Looks like I get to do this on my 21 JLR this weekend, got the rear blinking last week. Ive got the new sensor kit on order as well as the potting epoxy both should arrive tomorrow. Thanks for this great write up!

One question, when testing the 5 sensors in the kit, will incorrect sensors throw a code immediately once installed? Or do you need to drive around with them a little before they'll fail out? Just wondering if I can plug them in while the diff is open, check code while idling and if clear move on to potting right away, or if I really need to close, refill the diff, and drive around a bit for each sensor, or if there is a different procedure for testing the 5 sensors for the proper one.

No need to drive around. If the sensor is working, then light will go out and stay out.

You're welcome, man. Hope you get this worked out quickly.

 

[Aloicious]

Well, I got mine potted and they're curing now, luckily I don't need to go anywhere until Tuesday so ill let them cure tomorrow, install and test on mon and should be good to go.

Many thanks for the video, that helped immensely in understanding how to inject the epoxy.

Here's some info from my experience.

My bad rear sensor had no oil that I could see in it. So not sure the cause of the failure.

All 5 new sensors tested to work in the front diff, 4 of the 5 tested good in the rear diff (#4 was the only new one that gave a blinking light in the rear, but it worked in the front? Go figure)

Using a drill press and practicing drilling the known bad sensor made the drilling super easy. I used the bad sensor removed from the rear diff and set up the drill ress to barely get through the top plastic at full extension, so it would be impossible to drill too far in.

I since 4 of the 5 new sensors tested working in both front and rear positions, I went ahead and drilled and potted all the good ones, as well as the still good factory front sensor. So I guess ill have 2 to install and 3 spares that are already potted and ready if I ever need them.

The 25ml epoxy in the first post is plenty to pot all 5 sensors and still some left over, you could probably pot 6 total sensors with the 25ml amount.

Hope that helps someone.

Thanks again @chevymitchell for the write up!

 

[OldGuyNewJeep]

Well, I got mine potted and they're curing now, luckily I don't need to go anywhere until Tuesday so ill let them cure tomorrow, install and test on mon and should be good to go.

Many thanks for the video, that helped immensely in understanding how to inject the epoxy.

Here's some info from my experience.

My bad rear sensor had no oil that I could see in it. So not sure the cause of the failure.

All 5 new sensors tested to work in the front diff, 4 of the 5 tested good in the rear diff (#4 was the only new one that gave a blinking light in the rear, but it worked in the front? Go figure)

Using a drill press and practicing drilling the known bad sensor made the drilling super easy. I used the bad sensor removed from the rear diff and set up the drill ress to barely get through the top plastic at full extension, so it would be impossible to drill too far in.

I since 4 of the 5 new sensors tested working in both front and rear positions, I went ahead and drilled and potted all the good ones, as well as the still good factory front sensor. So I guess ill have 2 to install and 3 spares that are already potted and ready if I ever need them.

The 25ml epoxy in the first post is plenty to pot all 5 sensors and still some left over, you could probably pot 6 total sensors with the 25ml amount.

Hope that helps someone.

Thanks again @chevymitchell for the write up!

So to test the new sensors, do you just install, start the Jeep, then look to see if an error is thrown? No driving around or engaging lockers?

 

[Aloicious]

So to test the new sensors, do you just install, start the Jeep, then look to see if an error is thrown? No driving around or engaging lockers?

Yeah that's what I did, kept the diff open, plugged in and set the sensor in place, started the jeep and let it idle for 30-60 seconds, if no code or blinking locker light I considered it a pass. Thats my understanding of the process as was described in post 802 on this thread.

Ive currently got the newly potted sensors installed in the diffs and covers back on, but haven't filled them yet, letting the loctite cure first. Ill refill tomorrow morning and do a drive test.

 

[Aloicious]

Looks like everything is good so far, refilled and tested about 45 mins of driving, no blinking, no codes. Lockers engage and disengage properly. Ill keep an eye on but it appears to be a successful potting.

 

[roaniecowpony]

Hmm, I just pulled mine apart to do this and it looks like the design changed. 23 Gladiator Mojave. Build date 7/23

It would be even better if this system was backward compatible with the previous JL/JT design, AND they actually sold the parts. So far, I haven't seen where Jeep is selling any of these parts (differential, Locker, sensor, etc.). Hopefully, that will change, if this new system is more tolerant of field replacement.

 

[swampflyer]

Yeah that's what I did, kept the diff open, plugged in and set the sensor in place, started the jeep and let it idle for 30-60 seconds, if no code or blinking locker light I considered it a pass. Thats my understanding of the process as was described in post 802 on this thread.

Ive currently got the newly potted sensors installed in the diffs and covers back on, but haven't filled them yet, letting the loctite cure first. Ill refill tomorrow morning and do a drive test.

thanks, thats good information for us.

 

[ecidiego]

@chevymitchell feel like potting my 2021 JT Mojave's? 11k miles...changing fluid this weekend or next figure it should be done. No lights....yet.

Time and materials plus $50 tip for beer?

I do most things myself...added OEM trailcam etc....the drilling and precision work is where I tend to mess up. Thanks for this thread.

 

[chevymitchell]

@chevymitchell feel like potting my 2021 JT Mojave's? 11k miles...changing fluid this weekend or next figure it should be done. No lights....yet.

Time and materials plus $50 tip for beer?

I do most things myself...added OEM trailcam etc....the drilling and precision work is where I tend to mess up. Thanks for this thread.

Hey there. I can absolutely do that. I’ll pot them for free. Just need to get them to NC and back.

 

[legacy_etu]

It would be even better if this system was backward compatible with the previous JL/JT design, AND they actually sold the parts. So far, I haven't seen where Jeep is selling any of these parts (differential, Locker, sensor, etc.). Hopefully, that will change, if this new system is more tolerant of field replacement.

Agreed but honestly it would probably be cheaper (for everyone) if Jeep was to just spec. this sensor to be potted from the get go so folks could replace failed sensors and just be done with it. Speaking of course for those already riding around on the old sensor style.

 

[roaniecowpony]

Agreed but honestly it would probably be cheaper (for everyone) if Jeep was to just spec. this sensor to be potted from the get go so folks could replace failed sensors and just be done with it. Speaking of course for those already riding around on the old sensor style.

Yeah, Jeep needs to get off their ass and supply the parts for the diffs. The sensor alone is not my issue. I have potted sensors, but my front actuator coil is toast. I'm working on a hack using the Ford Bronco D44 parts. I'm about ready to install a Bronco actuator, but waiting on a couple minor parts.

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