Locker Position Sensor Potting - DANA 44

[legacy_etu]

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.

Ah, got it. I didn’t realize folks were having trouble with anything other than the sensor. Good luck with your Frankenstein setup.

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[Jeep Wick]

Great write up, I have both of mine curing right now. I just barely kissed the board drilling the holes, and when I zoom in on @chevymitchell pics his look identical. Rear sensor had oil in it, and I cleaned accordingly. Lights were intermittent on the dash last week but off when I started, so I'm hoping tomorrow's install will be a success.

Rubicon specs-
Rear bearing cap bolts 70 ft lbs
Front bearing cap bolts 80 ft lbs
Both cover bolts 30 ft lbs

Front fluid 1.03 L
Rear fluid 1.45 L

Sunday update-
Everything back together. I put 75w-140 in the rear to deal with the heat. Tested the lockers a few times, all is well. I had run the zautomotive bypass harnesses for awhile until the rear one broke a wire. I dare say the locker action is snappier than ever. Mission accomplished!!

 

[XtremeRetard]

Had mine replaced once already... Went again. This time I think I'll have to fix it myself as I've had gears added.. I'm guessing fca are unlikely to warrant it even under warranty miles..!?

Anyway sensor "looks" ok. Have ordered potting mix. Will clean up and test, then pot if all good.

Note the huge amount of metal on the metallic sensor arm...!

By the way. I didn't have to take the cap off to get my torx bit on there and take the sensor out.

 

[word302]

Had mine replaced once already... Went again. This time I think I'll have to fix it myself as I've had gears added.. I'm guessing fca are unlikely to warrant it even under warranty miles..!?

Anyway sensor "looks" ok. Have ordered potting mix. Will clean up and test, then pot if all good.

Note the huge amount of metal on the metallic sensor arm...!

By the way. I didn't have to take the cap off to get my torx bit on there and take the sensor out.

If you’re already throwing codes potting your sensors will likely do you no good as it’s too late. You may still be able to get them replaced under warranty. I doubt many dealers techs will know you have gears.

 

[XtremeRetard]

You are right. It's bad.

Plus the locker actuator is ill too now.. Slips in and out, rattles.

Booked in for warranty..

These lockers and sensors are pretty feeble. Mind you is done plenty of 8 and 9 rated trails.

 

[WannFly]

I am so glad I found this thread. I will be servicing my diffs soon and while I am in there, might as well get this done. QQ though for the red Loctite being used in the T-20. I am a Loctite virgin, so can someone tell me which one to use? Looking at 271 on their website tells me I would need a heat gun to remove that T-20 down the road?

Thank you @chevymitchell for putting the instructions together

 

[Jeep Wick]

I am so glad I found this thread. I will be servicing my diffs soon and while I am in there, might as well get this done. QQ though for the red Loctite being used in the T-20. I am a Loctite virgin, so can someone tell me which one to use? Looking at 271 on their website tells me I would need a heat gun to remove that T-20 down the road?

Thank you @chevymitchell for putting the instructions together

I'm a fan of blue loctite because it's serviceable, but I'm sure someone else will chime in.

 

[grimmjeeper]

I typically use blue loctite. And when in the diff, I go with the 243 blue which is oil tolerant. The 242 blue is good but has less oil tolerance.

 

[DHW]

My sensors and potting compound are arriving today. I'm using the same compound @chevymitchell recommended in the first post (https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1).

Can anyone tell me if it contains enough compound to pot all 5 sensors? I may just pot them all and let them dry first, then swap them out. That way my Jeep won't be out of commission for a day.

 

[word302]

My sensors and potting compound are arriving today. I'm using the same compound @chevymitchell recommended in the first post (https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1).

Can anyone tell me if it contains enough compound to pot all 5 sensors? I may just pot them all and let them dry first, then swap them out. That way my Jeep won't be out of commission for a day.

5? There's only 1 in each axle.

 

[mygreenkaw]

My sensors and potting compound are arriving today. I'm using the same compound @chevymitchell recommended in the first post (https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1).

Can anyone tell me if it contains enough compound to pot all 5 sensors? I may just pot them all and let them dry first, then swap them out. That way my Jeep won't be out of commission for a day.

@DHW

I potted mine quite some time ago, I just pulled, potted, and replaced. So only 2 sensor potted, seems to be plenty left so I'd say should have enough for 5.

 

[DHW]

5? There's only 1 in each axle.

The sensors come in packs of 5 and then it’s trial and error to see which one is correctly calibrated. Then you pot the right sensor and wait 24 hrs until it cures. If I pot all 5 first I can just leave the right sensor in, refill with oil and go.

 

[word302]

They sensors come in packs of 5 and then it’s trial and error to see which one is correctly calibrated. Then you pot the right sensor and wait 24 hrs until it cures. If I pot all 5 first I can just leave the right sensor in, refill with oil and go.

Ahh, gotcha. I didn't realize your factory sensors had already failed. I would think there should be enough compound to pot all 5. @chevymitchell probably knows exactly how far one tube will go.

 

[Mtpisgah]

The sensors come in packs of 5 and then it’s trial and error to see which one is correctly calibrated. Then you pot the right sensor and wait 24 hrs until it cures. If I pot all 5 first I can just leave the right sensor in, refill with oil and go.

What do you mean calibrated? I did not realize there was any different calibration to worry about.
I already have one failed sensor on my JT and am using the z automotive bypass. I need to pott the other sEnsor in my JT and both on my wife’s JL.

 

[chevymitchell]

Ahh, gotcha. I didn't realize your factory sensors had already failed. I would think there should be enough compound to pot all 5. @chevymitchell probably knows exactly how far one tube will go.

It can do all 5, for sure. And then some… never tested the max usage. Just depends on how much you bleed out of the sensors when potting them. It’ll do 5 though without a problem.

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