modman86
New member
Allright fellas, after hours of checking everything on the net only to find no resolution, I took on the job myself. Makes you wonder why even techs couldn't figure this out.
OK,the common problems lets start off with the two most common issues.
#1 What I call the "electronic clutch" for the lockers not disengaging or temporariliy engages
#2 The locker light keeps flashing
Do these not fall into the categories of your issues?
Here is your answer to why the problems happen. It's the spring sensor! after sometime of heavy wheelin metal flakes build up into the oil and guess what!? it clogs up the spring plunger and causes continuity inside the sensor and the light will keep flashing. Not only that, when the spring gets clogged, the pin does not return all the way causing the clutch to sit crooked! that leads to parts bending and not seating correctly.
Now this is what you need to do. Jack the rear wheels up from under the diff. Remove the diff cover, remove the bearing clamps on each side but remember to put it back exactly how it came off. This releases the pressure against the plunger on the sensor. Slightly spin the wheels and this will push the diff gear and all towards you to release the plunger and also allows you put back the plunger so the clutch plate lines up with the plunger catch. On vehicles that aren't serviced often you may need to pry the diff out a bit. You need to really soak the plunger in solvent to get all the muck out. When I did mine it had a lot of it inside. Took me several washes and compressed air to blow it out. I used a piece of metal strip to hold the pin open to allow the solvent to get inside to wash the muck out. Now the plunger is butter smooth. I strongly recommend to force some thick grease inside the plunger to help seal it as the warm oil is smooth enough to seep in. After doing this procedure and you want to check often to make sure your oil is clean. Everything is now working like it should. I took care of it before it got any worse. If you keep driving with the light blinking, you're going to make things worse. You're better off just removing the sensor temporarily. DO NOT do any bandaid fixes like using a screwdriver to force to the right, it will be bent from the back from a stuck plunger sensor and you'll end up buying a new locker. Remove the sensor immediately with an 8mm. plug the hole and see if it gets unstuck from there. Start doing the procedure I listed. All this should fix your issue if it has just started giving you problems. If you had drove your vehicle for quite some time like this, you can only hope it is still savable using this procedure.
OK,the common problems lets start off with the two most common issues.
#1 What I call the "electronic clutch" for the lockers not disengaging or temporariliy engages
#2 The locker light keeps flashing
Do these not fall into the categories of your issues?
Here is your answer to why the problems happen. It's the spring sensor! after sometime of heavy wheelin metal flakes build up into the oil and guess what!? it clogs up the spring plunger and causes continuity inside the sensor and the light will keep flashing. Not only that, when the spring gets clogged, the pin does not return all the way causing the clutch to sit crooked! that leads to parts bending and not seating correctly.
Now this is what you need to do. Jack the rear wheels up from under the diff. Remove the diff cover, remove the bearing clamps on each side but remember to put it back exactly how it came off. This releases the pressure against the plunger on the sensor. Slightly spin the wheels and this will push the diff gear and all towards you to release the plunger and also allows you put back the plunger so the clutch plate lines up with the plunger catch. On vehicles that aren't serviced often you may need to pry the diff out a bit. You need to really soak the plunger in solvent to get all the muck out. When I did mine it had a lot of it inside. Took me several washes and compressed air to blow it out. I used a piece of metal strip to hold the pin open to allow the solvent to get inside to wash the muck out. Now the plunger is butter smooth. I strongly recommend to force some thick grease inside the plunger to help seal it as the warm oil is smooth enough to seep in. After doing this procedure and you want to check often to make sure your oil is clean. Everything is now working like it should. I took care of it before it got any worse. If you keep driving with the light blinking, you're going to make things worse. You're better off just removing the sensor temporarily. DO NOT do any bandaid fixes like using a screwdriver to force to the right, it will be bent from the back from a stuck plunger sensor and you'll end up buying a new locker. Remove the sensor immediately with an 8mm. plug the hole and see if it gets unstuck from there. Start doing the procedure I listed. All this should fix your issue if it has just started giving you problems. If you had drove your vehicle for quite some time like this, you can only hope it is still savable using this procedure.
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