Hello

Today me change the Gears from a 2008 Rubicon to 4.88. After the Gaers are Install we make a Test drive. The Front Locker is working well. but the Rear Locker always unlock with a bad "Clonck". The Locker always flip out of the Locking Gears.
Back to the Garage we open the Rear Cover an Try to Switch the Locker. The Magnetic Coil have not enough Power to Close the Locker there are 1/10" missing of force. So the Locker can not Lock Compleate.
We messure Both Coils front and Rear both have 3.6 Ohms and 3,7-3,8 Ampere.
Did anybody know what kind of failure this is.

Whishes from Germany

Torsten

you should ask on jkownes.com
and ive herad if you put the plunger in wrong it breaks.

Sounds like you could have bent your plunger.

Hello

Now we found the failure. I don't know the English Words for the Parts but I made a Picture to understand what I mean.

There was a verry small Burr at the Coil. The Ring (Plunger) that move to the sheet Metall Ring have ~1/10" less force to lock compleate. I take the Burr of and make a small chamfer with a lathe. Now the Ring move ~1/10" over the Face where the Burr was. The Face with the Burr have contact to the Rotating Case of the Locker.

The JK have less then 3000 Miles on it!!!

http://jeep-power.de/cad/JK-Failure.jpg

Torsten