So, I swapped out the 4.10's for 5.13's and when I re-assembled the front axle, the locker was mechanically engaged by the plunger. I called David at Northridge and he told me I probably installed some plate backwards? I removed the entire front carrier again looking for something I installed wrong and it looks correct. I ended up shimming the plunger to back it off from the engagement ring so I can drive it for now. My front locker mechanically engages now when I hit the button, but the front axle lock light just flashes in the dash. What would you think would be the cause of this problem? Is there maybe supposed to be a spacer for the plunger/actautor between it and the axle housing that I possibly lost? David told me this is a common problem, but I just couldn't see what I installed wrong and I had to get it out of the shop for the weekend. Please Help!

 

I think before installing the carrier make locker connections. My mechanic didn't do that and bent the plunger. Plunger then needed to get replaced.

 

I removed the plunger from the front axle before I removed the carrier to begin with. It looked like I'd probably damage it removing the pinion gear.

 

FYI - Unfortunately not many people are brave enough to change our their ring and pinion, so be patient - you might have to wait a bit for some responses.

 

I'm a mechanic so I had to do it I've probably built around 50-60 differentials before, so it's not hard, but this is my first time messing with an electronic locker on a Dana 44. Only other ones I've built with lockers at all were on Hummers

 

All the plunger does it tell the system that the locker is engaged. When the lock flashes it means that the signal has been sent to engage the locker but the plunger shows that it the locker is not engaged. I installed the locker bypass switch that allows me to lock up anytime, any t/c position so my lock indicator flashes when I flip my bypass switch when I'm not in 4lo. I ignore it and let my tires tell me if I am locked or not. You won't hurt anything if you don't have the plunger.

 

ok, so here's the question....... as the carrier sits in the housing, is the plunger supposed to be positioned like the 1st picture or the second picture...

http://project-jk.com/wp-gallery2.php?g2_itemId=21653
http://project-jk.com/wp-gallery2.php?g2_itemId=21657

 

Second photo. When you flip the switch it engages a magnet that pulls the locker in. The locker is bolted to the plate which pulls the plunger. If it's ant consolation I ripped the wires off going to this switch so mine is broken.

 

well that's my problem! I installed the plunger after I installed the carrier and so therefore it can't go past the engagement ring. I need to pull out the carrier again, and install the plunger before I put in the carrier. Thanks for the help gentlemen!

 

X2. Mine was bent by the installer. I had to replace it and install it like Pic. #2.