Locker Position Sensor Potting - DANA 44

[WALEED.SHAH]

Good evening everyone.

I took the time today to run through the potting of my locker sensors. This seems to be a very frustrating point of failure for all of us. I have experienced it myself.

Here are the DIY steps you can follow to properly pot the sensors.

**Keep in mind the amount of time required for the potting material to cure. Tacky at 3-5 hours. 24 hour full cure. Best to do both sensors at the same time when you can wait, at least, overnight.

Also, please understand that this is a temporary fix to an issue we all hope FCA is going to remedy. Hopefully there is, at a minimum, a part number for this sensor we can order through Dealers and Distributors**

Jeep JL TQ Specs: https://www.jlwranglerforums.com/complete-torque-values-for-jeep-jl-wrangler/

Tools Required:

• 1/4" Ratchet
• 1/4" Drive T20 Bit
• 3/8" Drive Ratchet
• 3/8" Drive 10mm
• 1/2" Drive Ratchet
• 1/2" Drive 15mm
• Drill
• 3/32" Drill Bit
• Flathead Screwdriver
• Drain Pan

Parts Required:

• Teflon Tape
• Electrical Tape
• Sharpe/Marker
• Acetone (Optional)
• Red Loctite
• Dielectric Grease
• Shop towels or Microfiber Cloth
• 832HD Potting Compound (25mL)
  • https://www.amazon.com/MG-Chemicals...locphy=9009606&hvtargid=pla-376934479130&th=1

These steps are the same for the Front and Rear Axles.

• Using a 3/8" Drive ratchet, drain the diff fluid into your drain pan. Wait for the diff to finish draining. Clean the drain plug and apply teflon tape to the threads. Reinstall at this time.

• Using a 10mm socket, remove the diff cover bolts.

• Using a flathead (or finger tips), remove diff cover.
• Remove the reusable diff gasket.
• Using a 15mm socket, remove the R/H side Cap Bolts.
• Remove Cap Bolts with alignment plate. Keep the bolts with the plate so they go back in the same spots they came out of.

• Using a T20 bit, remove the screw holding the Locker Sensor in place.

• Using a flathead (or fingers), disengage connector safety clip.
• Remove Connector and Sensor.

• Wipe sensor off using a shop towel or microfiber cloth.
• Mark sensor as shown in the picture with a sharpe.

• Using a 3/32" drill bit, drill 3 holes as shown in the pictures. Be VERY careful with this step as the PCB (Circuit Board) is located very close to the clear cap on the sensor. Drill at a very low speed, with light pressure. We need 3 holes for this work properly. One is used to inject potting compound into the top side of the PCB, one for the bottom side of the PCB, and one to let air escape as we are injecting potting compound. Without an air escape, there will be air pockets and this whole thing will be for nothing.
• At this point, if your sensor has oil in it, would be a good time to clean it out. Spray some connector/electronics cleaner through each hole to rinse the sensor out. Be sure to let it dry completely before continuing to the next step. You don't want to dilute the potting compound too much. A little bit is ok.

• Inject potting compound as shown in the video. Once you inject the compound in the bottom hole, you will notice the air being pushed out first and then a rush of compound will come out when it's full.

• Once the sensor is full, wipe the top side off with a shop towel.
• Apply electrical tape over the two holes and set the sensor down on its top.

• Wipe off any excess potting compound and fill the void in the back of the sensor with more compound. Let sit for 3-5 hours. Once tacky, clean the sensor using Acetone so there isn't any left over potting material on the outside of the sensor once fully cured.

• Once cleaned, let sit for 24 hours. (At least 12 hours before reinstallation.)

• Once cured, install sensor in reverse order. (Use Dielectric Grease on the connector and Loctite on the T20 screw.)
• Install alignment plate and R/H side Cap Bolts. Be sure to TQ to spec. The TQ specs are different front to rear.
• Install Diff Cover.
• Service Diff.
• Test Locker System.

Hi brother,

Hope all well.

Ibjust purchased a 2019 rubicon JL. 4th week and the sensor light popped up. Didnt reach to the error point till now.

Its 2025 now. Your post is from 2020.

I just put in the epoxy like you have explained.

Now, I left it to dry.Will install it back once its dry.

But I was wondering, how is your sensor now? Is it working fine like how it was 5 years ago after your improvisation?

Looking forward to your kind reply.

Thanks,
Waleed

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[chevymitchell]

Hi brother,

Hope all well.

Ibjust purchased a 2019 rubicon JL. 4th week and the sensor light popped up. Didnt reach to the error point till now.

Its 2025 now. Your post is from 2020.

I just put in the epoxy like you have explained.

Now, I left it to dry.Will install it back once its dry.

But I was wondering, how is your sensor now? Is it working fine like how it was 5 years ago after your improvisation?

Looking forward to your kind reply.

Thanks,
Waleed

Good morning,

The original sensors this was done on was in a Jeep called Fat Ninja. It has since been sold, but yes, the sensors in it are still operating great. I've performed this on all the JL's I've owned except for Pain Train. No issues.

Jeep did release a revised sensor design which seems to be sealed from the factory. This was available in late 2024 and up JL's.

 

[WALEED.SHAH]

Good morning,

The original sensors this was done on was in a Jeep called Fat Ninja. It has since been sold, but yes, the sensors in it are still operating great. I've performed this on all the JL's I've owned except for Pain Train. No issues.

Jeep did release a revised sensor design which seems to be sealed from the factory. This was available in late 2024 and up JL's.

Hi dear,

I want you to know that the sensor is working like a wonder.

The problem was gone as if it never existed.

The function replies easier and quicker.

Thank you very much for the help bro.

It literally cost me 20$ for everything.

God bless you brother.

 

[chevymitchell]

Hi dear,

I want you to know that the sensor is working like a wonder.

The problem was gone as if it never existed.

The function replies easier and quicker.

Thank you very much for the help bro.

It literally cost me 20$ for everything.

God bless you brother.

You're very welcome. Happy to hear everything worked out for you!

 

[A&FJTJL]

Hello Guys. Alex here. Need some advice.
My wife has 2018 JL Rubicon, and after seeing this thread I potted her sensors front and back. Success, All worked great after putting it all back together.

Then....My 2023 JT Mohave I figured I needed to inspect it and when looking at the rear locker it was the old style sensor so I pulled it out and potted it. Put it all back together and now my dash is blinking and locker lever is also blinking. What the heck??? I never touched the PCB when drilling the holes. It wasn't blinking when I took it apart. Bummed here. Any ideas what could of happened or what I should do?

Thanks

Alex

 

[chevymitchell]

Hello Guys. Alex here. Need some advice.
My wife has 2018 JL Rubicon, and after seeing this thread I potted her sensors front and back. Success, All worked great after putting it all back together.

Then....My 2023 JT Mohave I figured I needed to inspect it and when looking at the rear locker it was the old style sensor so I pulled it out and potted it. Put it all back together and now my dash is blinking and locker lever is also blinking. What the heck??? I never touched the PCB when drilling the holes. It wasn't blinking when I took it apart. Bummed here. Any ideas what could of happened or what I should do?

Thanks

Alex

Alex,

You'll need to take it back apart and inspect the pins. This is normally caused by nicking the PCB or bending/pushing pins.

The potting process or material wouldn't cause any issues unless one was created in the process.

Inspect everything. Then after that, if the sensor is toast, you'll need to replace it.

 

[A&FJTJL]

OK. Thank you so much. I'll pull it apart tomorrow. I know I didn't nick the PCB as I drilled it by hand.

If it's not a bent pin....this will be the next course of action:

https://www.bamwholesaleparts.com/oem-parts/mopar-axle-sensor-kit-68544629aa


Thank you Shawn!

 

[LukeDagny]

OK. Thank you so much. I'll pull it apart tomorrow. I know I didn't nick the PCB as I drilled it by hand.

If it's not a bent pin....this will be the next course of action:

https://www.bamwholesaleparts.com/oem-parts/mopar-axle-sensor-kit-68544629aa


Thank you Shawn!

Alex,

FYI, the 25ml (?) epoxy syringe posted in the beginning of this thread is enough to pot all five sensors in the kit. Do them all at once.

 

[A&FJTJL]

Thanks LukeDagny. My luck as it goes, the good sensor that I just potted for my JT Mohave is now F'd up. So strange. No bent pins either. I was so careful drilling the holes with the bit in my fingers spinning it ever so slow. That is just my luck.

I've got the 5 replacement sensors on the way. What I was thinking of doing is... try them out 1 through 5 without putting the diff cover on and find the one that works when turning on the key....then pot it.

Thanks

Alex

 

[LukeDagny]

Thanks LukeDagny. My luck as it goes, the good sensor that I just potted for my JT Mohave is now F'd up. So strange. No bent pins either. I was so careful drilling the holes with the bit in my fingers spinning it ever so slow. That is just my luck.

I've got the 5 replacement sensors on the way. What I was thinking of doing is... try them out 1 through 5 without putting the diff cover on and find the one that works when turning on the key....then pot it.

Thanks

Alex

I tested mine with the diff cover off.

 

[A&FJTJL]

OK, the 5 sensors labeled 1 through 5 showed up. Wednesday is set aside to do this. Question is..for testing the new sensors...can they be just plugged into the electrical plug and just hang there while I go turn on the key and see if the flashing light goes away......or do they need to be plugged in and "in place" where they will be Torx bolted in.

Thanks,

Alex

 

[Terrymo]

I tested with the sensor in place with the diff cover off and my phone propped up to record. Pretty sure it needs to be in place to sense the position of the locker.

 

[LukeDagny]

I tested with the sensor in place with the diff cover off and my phone propped up to record. Pretty sure it needs to be in place to sense the position of the locker.

I did in place also. My understanding of how they work, says they need to be in place.

 

[A&FJTJL]

Thanks LukeDagny. I will make sure they are plugged in and in place before turning on the key. Let"s hope one of these fixes the blinking dash lights!

Alex

 

[A&FJTJL]

OK, I had the day today to do this testing and potting. I tested all 5 sensors. Sensors 1,3,5 all worked! The flashing lights vanished. Hooray! Sensors 2 and 4 did not do squat. So, I drilled and potted sensor #1. After drilling the 3 holes prior to potting... I put the sensor back in the truck to test it one more time, Success! So potted #1 sensor. Putting truck back together in the morning.

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