Locker Position Sensor Potting - DANA 44

[chevymitchell]

Does anybody know if the 2025 Rubicon's come with the sensor already potted? I thought I read somewhere that they did. But then a post in this thread made it sound like they didn't.

They switched to a different sensor altogether. Appears to be much less susceptible to the oil intrusion issue. Not sure when they switched though. I'd suggest still inspecting the housing to see if you have the new sensors or not.

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[Jeep Wick]

They switched to a different sensor altogether. Appears to be much less susceptible to the oil intrusion issue. Not sure when they switched though. I'd suggest still inspecting the housing to see if you have the new sensors or not.

I know we've had reports of the new sensors failing too, so they may be different but they are not perfect.

 

[nU7OuxIx]

They switched to a different sensor altogether. Appears to be much less susceptible to the oil intrusion issue. Not sure when they switched though. I'd suggest still inspecting the housing to see if you have the new sensors or not.

Thank you! I'm just planning for the future... We'll see if the stars align this year for an upgrade.

Is the new sensor available for replacement, or do we have to replace the entire axle again?

 

[BRuby]

When speaking about oil intrusion for the old sensor - was very surprised to see that the potting compound was seeping out from the contact seam of the translucent top where it meets with the main black housing.

So over time - the friction or adhesive bonds of the locker sensor components let go. This with just small pressure from the potting injector from filling. So one can imagine under high heat and high pressure - how the sensor can fill up with oil from that access joint alone.

Obviously Jeep recognized this as a significant flaw enough to redesign this component. But with new ones already failing - does not bode well.

Jeep should recognize that if the "new locker sensor" is also failing - they should not just sell replacements that will fail just as easily. But instead make sure these will do the job properly for the end user.

https://www.jlwranglerforums.com/forum/threads/locker-sensor-potting-failure.130790/

 

[pittperson]

My rear sensor just failed again. The first time it failed. I had to have the axel replaced the second time it was the “new” sensor now another “new” sensor. I’m just gonna let the light flash because it’s not affecting anything. The locker still works when I’m in 4WD. Ridiculous.

 

[DanW]

My rear sensor just failed again. The first time it failed. I had to have the axel replaced the second time it was the “new” sensor now another “new” sensor. I’m just gonna let the light flash because it’s not affecting anything. The locker still works when I’m in 4WD. Ridiculous.

Quadrate has a bypass for $149. Plug it in and forget it.

 

[ScottW511]

I just potted my sensors when doing a 25K oil change on my differentials. I really appreciate the information in this thread, made the job easy. I used the rivet spacer on my drill bit, had 2mm of bit exposed and this was perfect for drilling through the plastic without going deeper than needed.

I didn't appear to have any oil in either sensor and never had a locker issue but I'm glad to have done this preventative maintenance.

 

[Jeep Wick]

My rear sensor just failed again. The first time it failed. I had to have the axel replaced the second time it was the “new” sensor now another “new” sensor. I’m just gonna let the light flash because it’s not affecting anything. The locker still works when I’m in 4WD. Ridiculous.

If you don't want to pot the sensor, just get the Zautomotive bypass harness and be done with it.

 

[chevymitchell]

If you don't want to pot the sensor, just get the Zautomotive bypass harness and be done with it.

Just remember that you lose the "in-transit" function when you bypass the sensor wiring with these harnesses.

Once you're locked up, make sure you're unlocked before taking off. You'll have to do this by feel since you won't have the blinking "in-transit" function of the locker sensor to tell you you're locked or unlocked. The locker doesn't work like a light switch. It still needs to rotate into a position where it's not bound up to engage or disengage. However, the bypass harnesses will make it appear it's on or off. The light will go off but you can still be locked and vice versa.

 

[pittperson]

Sweet. Just bought the bypass.

Quadrate has a bypass for $149. Plug it in and forget it.

 

[Terrymo]

I know I was hesitant to do the potting of the sensor, but using the great instructions and pics from @chevymitchell as well as input from others in this thread it was easy to do. If you have basic mechanical ability and some patience there’s no reason you can’t do this.

 

[pittperson]

I have no doubt I can do this work. Maybe I’ll do it someday, but for now I’m taking the easy route.

Having to do this 3 times is nuts. I’ve gotten more life out of tires, a wear and tear part. /rant

 

[JeepCares]

My rear sensor just failed again. The first time it failed. I had to have the axel replaced the second time it was the “new” sensor now another “new” sensor. I’m just gonna let the light flash because it’s not affecting anything. The locker still works when I’m in 4WD. Ridiculous.

We are sorry to hear about this! If you decide to schedule an appointment with the dealership and need any assistance, please feel free to send us a private message.

Yenori
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[moeman]

Quadrate has a bypass for $149. Plug it in and forget it.

You can get the Chinese knockoff for about $25. All you have to do is get a Dremel and burr out the plastic piece in the connector so it can fit

 

[Terrymo]

You can get the Chinese knockoff for about $25. All you have to do is get a Dremel and burr out the plastic piece in the connector so it can fit

I potted my sensors for $20 but still carry the Z automotive bypass harness in my Jeep.

https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1

Do you have a link for what you’re referring to?

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