Well I think I'm going on my 5th repair of the rear diff speed sensor and I read somewhere that the CRD had a TSB for the speed sensor.
I have a guy near me that had fixed it a few times and we have tried a few different speed sensors and a few repairs was the wiring.
It just failed again last night and my girlfriend is not happy! I plan on just getting her something else to drive soon and I'll use the CRD as my gas (diesel) getter and let my F250 diesel hang out in the garage.

Just wanted to know if anyone has seen similar failures with the CRD and has a fix that lasted longer then 1 year. At this point every fall I have to fix it again! The wiring has been "beefed" up and lengthened to attempt to relieve some stress on the wiring.

The only time I have someone else work on my vehicles is when its related to wiring or serious sensor issues that I don't have the equipment to diagnose. The guy I use for this (Rogers Automotive in Dearborn MI) is fair priced and very quick in fixing this and I think he has ran out of ideas on this.

Thanks for any help!!!!

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-05 Dark Khaki Limited CRD. GDE ECO tune. In-tank lift pump, Transgo doo doo kit, B&M trans cooler, replaced trans solenoid pack and filters, Newer Michelin tires, Timing belt with all related parts replaced at 110,000miles.

How is your guy splicing the wires? Solder and heat shrink would be the most reliable. Under vehicle, butt splices would be a poor choice.

The sensor really should be pretty long lived. It has no moving parts. It just produces a pulse in response to a toothed ring passing close to it.

Does the sensor have any visible damage? Does your differential get unusually hot? Heat could kill the sensor I suppose.

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Matt B.

05 Limited CRD. Bought it new. 112k on the clock now.

GDE Eco-tune, rear differential drain plug (drilled and tapped the pumpkin), transmission pan drain plug, Fumoto oil valve, fuel filler neck restriction removed, front hitch, Hayden fan clutch, Sears P1 battery since 08, Mobil 1 5w40, 5 volt glow plugs, DIY timing belt at 109k

I soldered the wires,after cutting the connector off,directly to the speed sensor pins then filled the speed sensor connector end with RTV.Problem solved for me since the wires broke inside the male connector end.Well solved it for about 3 years till I had to move the whole thing to the t-case to run the speedo.

When it happened to me, the cause was a broken wire inside the plastic sheathing.

The wire is so thin that it snaps / breaks from the excessive whip like shaking and you will never see where the break occured becasue it is not visible, it is hiding inside the sheathing.

You'll have to test the wires for continuation, from past experience the break usually happens between the first 16" away from the sensor.

Replace the wires and connector with the heavier duty wires from the dealer.

Test the connection by only tieing the wires without finalizing the connection and driving it forward for 15 feet.... if the wires are not crossed the light will go off if the wires are crossed the lights stay on and in this case just swap the wires and wrap them tight.

My experience is that the wires need replacing not the sensor.

I learned this the hard way.....I have 4 good sensors on the shelf to prove it.

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2006 Liberty Limited CRD, Deep Beryl Green, Yeti tune, Arp studs, new cams, rockers, lifters, TB. "Green Monster"
2005 Liberty Sport CRD, Deep Beryl Green, GDE Hot Tune, ARP studs. "Rocket"
1982 Fiat 124 Spider Convertible. "Fiona"

This may be the same problem I am experiencing as well. I have replaced my sensor twice and the connector once. The problem is intermittent and seems to occur at random times while driving, especially in a turn. I have been quite frustrated since it disables my ABS, odometer, and also screws with my temp in the EVICS. This last time, the lights have come on and stayed on so maybe it's chewed all the way through now.

Is there a TSB? Is there just a beefier wiring harness, or should I just cut and solder a thicker gauge in place? After I replaced the last connector, I put a plastic wiring sheath over the wires to protect it, that doesn't seem to help.

Thanks, Rob

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05 CRD Limited- Frankie IIP Lift w/spacer JBA 6" springs in rear- ProComp Street Lock steel wheels - ARB Bumper- Warn M8000 w/Synthetic Line- RRO Rails/Roof Rack- 2300W Power Inverter- 4.10 gears w/ARB Air Lockers F&R- JBA A-Arms- Viar Air Compressor/Tank- RL Super Skink Sliders-JBA Steel D30S Front Diff, Non-shiny new Paint, OD Green

I did read the TSB for failing diff sensors somewhere on one of the Jeep forums but I cannot find it again

However I do remember it going something like this:

2005 KJs have a chance of the rear diff speed sensor failing.

This is due to the incorrect lubricant inside the rear differential

Owners are to take their vehicles to a Jeep dealer where the rear diff lubricant will be replaced with the correct lubricant and a new speed sensor will be fitted.

This makes one wonder what lubricant they put in the diffs of some 2005 KJs to eat away at the sensor.

I will try find this darn TSB but I would suggest that people having this problem should drain their rear diffs....if they have not already done so...and re-fill with the correct lubricant and replace the sensor.


Edit: OK found it TSB-08-048-05

Link is here: http://www.jeepkj.com/forum/f212/tsb-08-048-05-differential-mounted-rear-wheel-speed-sensor-27665/

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2002 Export CRD 2.5 Sport

Try TSB 08-048-05 SEP 05 Brakes/Drivetrain - MIL/ABS Lamps ON/Possible DTC P0501

I don't have a copy (email me one if you find it pls) so I don't know for sure but it's the only one on my list that looks promising.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

I've been having this same problem with my brakes. The lights would go on every time I drove at different distances down the road.

Here's my problem. I was inspecting all of my wires today while rotating tires, and I proceeded to break the two wires on the rear wheel sped sensors right next to the connection over the differential. I have already ordered the new sensor from amazon, but how do I buy a newer wiring harness that includes the plug that will fit into the sensor? It sounds like several of you are simply soldering the old wired to the sensor directly, but I would like to have the proper connection if I can. Does anyone have a part number?

Thanks in advance.

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2005 Black KJ Sport CRD,
GDE Full Torque ECO TUNE, GDE Transmission ECO Tune,
Samco British Racing Green Hoses
Build Date 1/05
200k miles.
Original Owner

Gotta go to the dealership and buy the pigtail connector.Most likely a special order part and around $25-$50.

Thanks tjkj,

I'm not even sure that this will solve my problem. I saw in a different post that you said the rear sensor will NOT trip both the abs and brake light while killing the odometer and trip. Is that correct? Do you think that I still have a front sensor out? I checked the wires (both front bearings have been replaced in the last two years) and the wires seem fine all the way up into the engine bay.

Now that I ripped the entire rear wire out, the jeep starts with the brake and the abs lights on. Before I ripped it completely out, I would get only the abs light at start.... It would go out after a few feet like others have stated, and then a few miles down the road both lights would come on.

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2005 Black KJ Sport CRD,
GDE Full Torque ECO TUNE, GDE Transmission ECO Tune,
Samco British Racing Green Hoses
Build Date 1/05
200k miles.
Original Owner