Just got the rear axle back from the axle shop now the rear locker is staying locked. The light is not on and when you put the transfer case in 4lo and hit the rear switch the light just flashes until you hit the button to turn it off. Could this be a wiring problem or internal?

Chris

 

If, at the axle shop, they had the carrier out, they probably installed the lock sensor on the wrong side of the lock plate.

If this is the case:
Take it back and tell them the sensor is supposed to go in before the carrier.

With some luck, nothing is damaged.

This is what the sensor looks like when installed wrong:


This is what the sensor looks like when installed correctly:

 

For some reason I cannot get your pictures to load?

Chris

 

Try clicking on the links to them.

Showing wrong installation:
http://project-jk.com/gallery2/main....2_itemId=21654

Showing correct installation:
http://project-jk.com/gallery2/main....2_itemId=21658

 

Thank you!!! The links worked.

Chris

 

Just pulled the cover off plunger is on the wrong side of ring. I am guessing the locker has to come out?

 

It's hard to see on my monitor, but it looks like the lock plate is being pushed to the left by something. Must be the sensor plunger; in which case, yes, the diff has to come out.

The mechanic probably installed the sensor after the differential.

The proper sequence is:
Remove diff
Remove sensor
Install sensor
Install diff

In your situation, you may now have to remove the sensor first.


Can you take a better pic that will clearly show the sensor on the wrong side of the lock plate? It would be good to have the pic for future reference.

 

I will try again to get a pic that clearly shows the plunger on the plunger on the wrong side. I tried several times this morning and those pics were the best.

Chris

 

Could not get any better pics. I read that it cannot be done but I somehow got the plunger on the correct side of the lock ring with the carrier in place. I remove the plunger and checked to make sure it was not bent and operated freely, then I tapped a wedge in to hold the lock ring tight to the magnet, the plunger is not long enough to get on the correct side of ring without threads being started. I bent a straight screwdriver so I could hold the plunger out. I held the plunger out and started to thread the sensor into the housing. The threads were a little hard to start because the plunger was on top of the ring instead of behind the ring where it goes. I then turned the sensor in a few turns and used the screwdriver to pop the plunger into the correct position. I checked and luckily did not bend the plunger as it still moves in and out freely. I also think there was quite a bit of luck involved!!!

Chris

 

Thanks for the description of how you properly installed the sensor after the fact.

I'm sure it will be helpful to people in the future.