Locker Position Sensor Potting - DANA 44

[chevymitchell]

will the 2024 my sensor work on prior my?

No. The solenoid/plate assembly is completely different.

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[Fftoddster]

Thank you. I may let Jeep take care of it then. If they only do the rear under warranty then I will do front myself.

 

[swampflyer]

No. The solenoid/plate assembly is completely different.

Well, isn’t that dandy? They screw us again. The axle probably wouldn’t work if you changed it out either. Oh well time to go to 60s if I have that problem again. thanks for the info

 

[Terrymo]

Well, isn’t that dandy? They screw us again. The axle probably wouldn’t work if you changed it out either. Oh well time to go to 60s if I have that problem again. thanks for the info

It’s always time to go to 60s though right?

 

[swampflyer]

It’s always time to go to 60s though right?

 

[swampflyer]

Especially since they now have a remedy where you can use your factory locker position switch for aftermarket axle lockers ie eaton.

 

[JeepCares]

Does this fall under the powertrain warranty? After the basic 3 yr warranty is up?

Hi there! If you would like us to check on the status of the warranty, please send us a private message with the last eight characters of the VIN and mileage.

Yenori
Jeep Cares

 

[Fftoddster]

Hi there! If you would like us to check on the status of the warranty, please send us a private message with the last eight characters of the VIN and mileage.

Yenori
Jeep Cares

I sent the info. I know I will be good based on year and miles.
My question really was is the sensor repair covered under the powertrain warranty or will they try to claim it’s electrical and not covered?
I would like to know before I take it to the dealer.

 

[chevymitchell]

I sent the info. I know I will be good based on year and miles.
My question really was is the sensor repair covered under the powertrain warranty or will they try to claim it’s electrical and not covered?
I would like to know before I take it to the dealer.

The sensor is a sub component of the locker/carrier assembly.

Initially, they were replacing the entire axle because of it being a sub component.

Now that they have released the sensor kit, it should be under the powertrain but the kit allows them to repair it rather than replacing the whole axle.

 

[LukeDagny]

Does this fall under the powertrain warranty? After the basic 3 yr warranty is up?

I bought my certified pre-owned '21 JLUR with 20K miles in early 2024. It came with a 7 year/100K mile Chrysler CPO extended warranty.

When my light came on, the 3 year/36K mile warranty had expired. My local dealer said my sensor was not covered because it was electrical, and charged me $150 diagnostic fee. He diagnosed the problem as a $7 rubber seal. That didn't fix the problem.

I paid ~$135 for the 5 sensor kit, bought an epoxy syringe and fixed it myself. On 20/20 hindsight, it would have been cheaper if I didn't invovle the dealer.

 

[Fftoddster]

That’s exactly what I don’t want to happen. Hoping to get something from Jeep care one way or other but have not heard back from them. That’s BS if they have been replacing the whole axle assembly for a bad sensor and now that sensor is available they won’t even cover the sensor replacement?
I sure hope that is not the case!

 

[ym0bc1]

I guess this MG 832HD compound has been time proven.
Was a little bit concerned about it's cured hardness. With temperature cycles, would it damage electronics on the PCB or the casing itself?

 

[chevymitchell]

I guess this MG 832HD compound has been time proven.
Was a little bit concerned about it's cured hardness. With temperature cycles, would it damage electronics on the PCB or the casing itself?

Not at all.

Its cured service temp range is -40 to 150 deg C.

If your diff hits 150 C (~300 F), then you’ve got bigger problems.

 

[D.Anderson]

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.

Great thread. My problem was locker wire rubbing against frame and shortening out.

 

[virkdoc]

New to me jeep JL 2022 Rubicon 4 door. All was ok when we picked her up but as soon as we hit the highway doing about 60mph/100kmph the rocker light flashes on the dash and the switch. It was intermittent the first few days. Then it disappeared and now appeared again.
I have ordered a new sensor from eBay but it will take a few weeks before it crawls back to india.
Question is:
Can the old sensor still be saved?
Since it comes and goes does it mean it still has some life left and if I clean it and pot it chances are it will work?

But what a beautiful thread.

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