HELP! 05 Rubicon electric locker won't disengage....

[jonsolbe]

I just had the inner and outer rear axle seals on my 05 Rubicon replaced, but now the rear electric locker will not disengage. I've tried cycling the locker switches while in 4L, during which the front locker engages/disengages appropriately, but the rear locker light just flashes and will not do anything.

Has anyone else had this problem? Is there anything you can think of that could have been re-installed incorrectly which would not allow the rear locker to un-lock itself?

Thanks boys,

Jon

 

[jonsolbe]

Update:

 

[jonsolbe]

Arg, I can't get the pictures to look larger than thumbnails. Never-the-less, the plot thickens....

When we pulled the rear diff cover off again, the locker plate (can see it on the photo, on the left side) seemed to be sitting in there at an angle, as if something wasn't letting the top half completely disengage. We unscrewed the locker indicator switch from the top, front of the differential, and as that was turning out of its hole, the locking plate also moved back into it's normal position, completely to the right and the axles disengaged and were free to rotate independently again. The air compressor also moves the plate in and out, as it's supposed to. When the switch is screwed back into the differential housing, once again, the top of the locker plate moves to the left and partially engages the locker.

To test this theory, I unscrewed the front axle's locker indicator and sure enough, when the little switch is pulled out (simulating air pressure moving the locker plate into position), the dash light front locker comes steadily on. But now, when I screw the indicator back into place, the front axle becomes completely locked and now will not come unlocked!

Has anyone ever dealt with these locker indicator switches? Is it possible that inside the differential they have to be in the perfect position, with their heads on the inside of the locer plate?

 

[SteelHeadz]

Make sure the pressure plates are seated correctly in the dog clutch slots. With a 1/4 inch drill bit check the clearance between the actuator and actuator pressure plate at the top and the bottom.

1. CAUTION: If clearance is not correct, indicator switch plunger may be on top of the actuator or actuator mounting tabs may be bent. Failure to heed caution may result in damage.