A lot of times the plunger is damaged during gear installs. My plunger was fine for 2 years after new gears but last season it would keep getting jammed and the locker wouldn't disengage. After manually disengaging the locker several times I had enough. Pulled the plunger out and plugged the hole in the diff where the plunger goes in. Locker engages & disengages without issue now. The only issue is the light will flash when you turn the locker on as there is no sensor back there but you'll know when the lockers is on. Cheap solution and I am happy with it. Jeeps been running 37s for 3 years now.

Good luck

 

Haha yeah and maybe he he'll say your brake light fluid is next on the list for replacement!

 

Sounds to me like the reason the shop sees alot of trouble with Rubicons is because THEY screw them up on every set they do... And NO they can't jump the plate after they are installed properly, let alone caused by big tires...

 

I could understand after 2 years, but I have less than 3000 miles on my jeep and have had to replace the front and rear sensors twice, has to be the shop.

 

Sorry, I had to laugh at this guy. HE'S been re-gearing these and every time HE does it the plunger "jumps to the other side with big tires". How many is HE re-gearing with stock sized tires? It's a matter of work quality and correctness, we don't live in a Harry Potter world and parts don't magically move about like staircases. The really funny thing is HE knows and believes it's happening and HE is a great mechanic that can't be at fault so HE creates a scenario in his mind to keep that safe and true.