Rubicon Lockers Sensor Gone Bad. Repair or Replace

[aFatBird]

What does "pott the sensors" mean? Drill em out to empty/dysfunctional? Remove?? Thanks!

You drill a hole in them and fill them with a sealant so they don't fail due to oil or gunk getting in them

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[Mtpisgah]

https://www.jlwranglerforums.com/forum/threads/locker-position-sensor-potting-dana-44.59581/
start at the first page. Everything you need to know.

 

[Uparms]

You drill a hole in them and fill them with a sealant so they don't fail due to oil or gunk getting in them

Thank You.

 

[Rusty PW]

Op. When the dealer fixes the locker. Ask to see the locker sensor. It should be all white. It lube has gotten into it. You will see black in it. The more black. The more lube in it.

For some reason. The factory does not pot the sensors. Some leak, some don't. I potted mine.

 

[Duece McCracken]

I read threads like this, and am very happy that I also potted my sensors.

 

[Gladiator Brad 704]

My rear sensor started causing intermittent dash warning light at about 15K miles. (Service locker or something like that.) Dealer said they couldn't do anything unless they saw the light and claimed the computer showed nothing in the memory. Also claimed they knew nothing about any sensor problems. When I tried to show them some information they were not interested.

I really don't want them working on my diff. anyway, I am not really impressed with their capabilities. Don't want them replacing my entire dif. either.

Installed the Z- Locker by pass and have had no problems, now at 27K. Everything works perfectly. Another year or so and I will start building my truck for the sand and most likely start with bigger axels with lower gears.

 

[ScoGlad21]

My sensor went out at roughly 12,000 while I was towing through the mountains during the summer months. I read somewhere that towing increases the probability of failure. It’s completely ludicrous that the warranty fix is replacing the axle which is the route I went while under warranty.

 

[BlackDog]

I've had this happen twice while under warranty. First time they replaced the axle, second time (a few months ago) they replaced the sensor only.

The light has flashed a few times since so there may be a third in my future.

 

[aFatBird]

So far, my dealership has only told me there is no ETA on the new sensor so I'm just stuck waiting atm. I just want to have lockers working before I go play in the snow.

 

[zuki_dan]

The Z automotive harness will take care of the light and bypass the sensor itself.

Under warranty I would still let them fix it.

If doing gear swap I highly recommend potting the sensors. Really easy to do while swapping gears. No issues with my potted sensors.

Factory fill rear gear oil was really nasty at 7k and there was all kinds of wear metal stuck to the sensor.

 

[Maximus Gladius]

I potted both sensors today and I found a slice in the white connector wire for the rear locker. The locker worked prior to the potting today. Is this a problem?

 

[Duece McCracken]

I potted both sensors today and I found a slice in the white connector wire for the rear locker. The locker worked prior to the potting today. Is this a problem?

Well, since you potted the sensors, that wont be an additional oil pathway into the sensor.

If thats a ground, no worries for sure. I doubt if its a positive, that it has enough voltage to ground through the metal in used gear oil.


Proper way to fix would to de-pin it and heatshrink over. I can't reall drum up a scenario where thats going to be a failure though.

Hopefully someone else has insight.

 

[Maximus Gladius]

My experience with doing this exercise was very good. Thanks to all those that gave examples and photos. It was good to pull the diff covers, clean out the inside and spray it down with brake cleaner and inspect gears.

Sensors were good so that was a bonus. The removal of the sensorwas easy with just taking out the single torx screw.

The rear magnet had a good amount of filings and sludge on it.

I waited the 24 hours for the potting material to cure then put it all back together and went out for a drive and tested the lockers. WOW!

So before, when engaging the lockers the locker symbol on the dash would blink up to 10 times before giving steady signal and that would be the same for release. Now, after the job, lockers engage and release on the second blink, both front and back. The response is immediate!

I didn’t do anything about the split wire casing, it works. If it becomes an issue, I’ll find the replacement wire and swap it out.

 

[Gladiator Brad 704]

When you refer to " potting material ", what exactly did you use? Based on the amount of metal present on your magnets I will likely remove my covers and clean out the diff. How many miles on the truck? Thanks for the Info.

 

[Maximus Gladius]

When you refer to " potting material ", what exactly did you use? Based on the amount of metal present on your magnets I will likely remove my covers and clean out the diff. How many miles on the truck? Thanks for the Info.

The stuff I used is excellent. (See pics) Got it off Amazon Canada. 25ml is plenty. As you can see, this is what’s left from filling both sensors. Odometer is at 49k kms (30,447 miles)

I should also add to the story that sometimes when I tried engaging the lockers, the symbol would just flash long enough to quit. I’d have to keep trying until it would finally work.

Works like a dream now.

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