Locker indicator replacement, 05 Rubicon

[jonsolbe]

Has anyone ever replaced the locker indicator switches on an 05 Rubicon? They screw into the top of the differential housing and when the locker is engaged, the locker plate pulls the switch which turns the light on up on the dash.

We replaced the rear seals and after reinstalling the carrier, it seems that the locker indicator switch is pushing on the locker plate and partially engaging the locker. I unscrewed the front diff locker indicator switch and it came out super easily. When I tried to replace it, now the front locker is also partially engaged. There has to be a way to replace these switches without removing the entire carrier assembly.

Any advice?

 

[SteelHeadz]

I haven't done it any other way than what the factory service manual procedures. There are a few special tools involved in this procedure.
[h=3]REMOVAL[/h]

1. Remove drain plug from the differential housing.
2. Disconnect indicator switch harness and remove connector from differential cover (INDICATOR SWITCH CONNECTOR).
3. Remove differential housing cover.
4. Remove axle shafts.
5. Remove pressure hose from actuator assembly (PRESSURE HOSE).
6. Note the reference letters stamped on the bearing caps and housing machined sealing surface (LOCATION MARKS).
7. Loosen differential bearing cap bolts.
8. Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes (SPREADER LOCATION). Install hold-down clamps and tighten the turnbuckle finger-tight.
9. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud (DIAL INDICATOR LOCATION). Load indicator plunger against the opposite side of the housing and zero the indicator. CAUTION: Never spread the housing over 0.38 mm (0.015 in). Failure to heed caution may result in damage.
   
10. Spread housing while measuring the distance with the dial indicator (SPREAD DIFFERENTIAL CASE).
11. Remove dial indicator.
12. Remove differential bearing cap bolts and ring gear side bearing cap.
13. Remove differential from housing with pinion gear side bearing cap (DIFFERENTIAL) and tag differential bearing cups and preload shims to indicate location. CAUTION: Do not bend actuator mounting tabs, during differential removal. Failure to heed caution may result in damage.
    
14. Remove spreader from housing.
15. Remove indicator switch (INDICATOR SWITCH) from differential housing.
16. Clean the housing cavity with flushing oil, light engine oil or lint free cloth. NOTE: Do not use water, steam, kerosene or gasoline for cleaning.