I installed a Rugged Ridge SYE. As you can see in the pictures, the speedo sensor was installed in the 32-38 position for my green 34 tooth gear. Should be perfect, and in fact it was for about 1000 miles. The problem: speedo and odo stopped, CIL on. I looked into it, and both the speedo sensor gear and output shaft gear are chewed up (see remaining picture of sensor gear).
Has anyone seen this that had more of an issue than just a misclocked sensor housing? I ordered a new blue gear for the RR SYE rear output shaft here:
I'm hesitant though because I don't want to chew another $10 output shaft gear and $40 speedo gear, not to mention having to tear into the case to fix it. So has anyone seen this or know why I would chew up a gear even with it (supposedly) clocked right? The closest answer I can find is post #27 here:
Foreign material would seem very unlikely. The speedo gear sits at the top of the transfer case, it would probably be the last thing affected by foreign objects (chain, sprockets, or pump would see it first). Also, any debris would cause gear chipping rather than this smooth wear pattern that is uniform around the whole gear. It is possible I guess. Have you seen an issue like this caused by contamination before? I'll have to open the case to fix it, so I guess I'll get a nice good look.
I think that "rugged ridge" says a lot here. For plastic to last long in this application it has to be pretty tough. I'm guessing that these plastic materials were just not up to this application. I have no experience with rugged ridge speedo gears but I have a lot of bad experience with a large variety of other rugged ridge Jeep parts. I don't buy that brand any more. I'm pretty sure that is is the same company as Omix Ada.
Agreed. I would have held out for a JB Conversion SYE, but I had to have it installed only a few days before Jeep Safari. The Rugged Ridge was the only thing I could find in stock locally. Regardless, I believe that the blue gear inside the transfer case is a stock part from a 241 transfer case and the speed sensor didn't change other than being bolted into a different housing. I guess it would be possible that RR cheaped out on the plastic compared to an OEM part.
I finally got the drive gear in the mail and switched it out today. Here's a picture of the effect on the drive gear. I was surprised to see how close to the front edge of the gear (front as in towards the front of the vehicle) that the wear occurred. I don't know if that has anything to do with why it failed or not.
Regardless, the new drive gear had one side with a wider lip and I put that side toward the rear of the vehicle. I found a new speedometer sensor with the same 34 tooth gear for $5 at the local junkyard. When installing, I removed the o-ring on the speedo sensor and rotated it in the transfer case housing until I felt the interference with the drive gear. It felt good right back at the 32-38 spot, same as it was before. We'll see if the issue resurfaces. Thanks for everyones input...
Did the issue ever resurface? I'm running into the same problem in that I can't find a position that feels good for the speedo gear. The correct index for my gear (41 tooth) doesn't mesh well with the SYE gear and causes it to chew. I'm going to play around with the other positions, but something about using the 32-38 tooth position for a 41 tooth gear doesn't sit right with me. I guess I can also use an intermediate position but then the fork that holds the speedo sensor in will not align with the slots. Has anyone else had to do this with a SYE to get the speedo to work and mesh correctly?
I haven't had any issues since the repair, and that's been a couple of thousand miles now. I just think the Rugged Ridge supplied drive gear (the blue one) had some plastic formulation issues.
The thing that really helped me determine the correct speedo placement was to remove the o-ring on the sensor housing. Spin it around until the sensor won't sit flat against the TC. As for using the 32-38 position for a 41 tooth gear, the tail housing of your SYE could be significantly different geometry than the stock alignment. I wouldn't worry about that as long as the sensor fits okay. I agree with you though, not having the fork aligned in the slots would bug me. Luckily mine went right into the slots.