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 [Install] Speedo Gear and Sensor Replacement Guide « View previous topic :: View next topic » 
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PostPosted: Fri Apr 04, 2008 10:04 pm    Post subject: [Install] Speedo Gear and Sensor Replacement Guide Reply with quote

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Speedo Gear and Sensor Replacement Guide
Fix that malfunctioning speedometer!


One day I was driving back home and all of sudden guage started acting up. I thought it was just my gauge being disconnected from the ECM causing it to dance around. Well, following that I got a "Check Engine" light. Then I tried coming to a stop at a light and naturally hit the clutch to shift into neutral. Guess what, the engine stalled and died leaving me with no power steering or the brake. Good thing I started slowing down earlier than usual, I had enough time to recrank the engine.

It fired right up and gave me the brake and the steering back. I was just puzzled as to why the engine died. Well, I got to use the CarChip E/X for the second time to check on the DTC.

The trouble code indicated that there was no signal from the speedosensor. Time to change the speedo sensor.

The speedosensor is located on the rear of the transfercase of the Jeep TJs. As shown in the picture above.

You can use this guide to change out the speedo gear for correcting your speedometer for different tire size.

Possible Symptoms
Erratic speedometer, Stalling engine when the clutch is applied as the vehicle comes to a stop.

Tools and Parts Needed
Basic Socket Set
New Speedosensor (Part Number 56028183 @ $31.75)
New Speedogear (If used, Part Number 520676xx: xx is replaced by number of teeth on the gear.)

Job Hours
30 Minutes

You are dealing with a component that spins along with the drivetrain. Improper installation can cause severe damages. DDTJ does not guarantee the outcome of your repair and is not responsible
for any damages that occur.

1. Locate the speedosensor on the transfer case. It is located on the back of the transfercase facing the rear. It should have a red tab as shown.

2. Remove the wiring harness by sliding the locking tab towards you and squeeze the secure tab and pull the harness. Remove the bolt as shown. Set the metal clip and the bolt in a safe place.

3. Pull the speedo sensor assembly away from the transfercase.

4. Separate the speedo gear from the sensor assembly. Simply pull them apart.

5. Once gear is separated, remove the bolt shown below. Separate the sensor portion from the cone housing.

This is what the new part looks like from the dealer. Another shot of the part shown on the below.

6. Install the new sensor into the housing. Do not overtorque the bolt. Install the speedo gear by pushing it in until you hear a click. You should not be able to freely remove the gear but yet it should still be freely rotating.

7. Clean the mouting surface.

8. OPTIONAL: The O ring on my speedosensor has a little tear on it and it will leak. So I just applied some RTV around the sensor to keep it from leaking. I have been doing this for about 4 years and this never leaked.

9. Install the retainer and the bolt. Notice the indexes shown on the speedosensor housing. Match that to the number of the teeth on the speedogear you are using and bolt it down. DO NOT OVER TIGHTEN IT!

10. Reconnect the wiring harness and push in the red tab to keep the wire coming loose from the sensor assembly. You are done!


I tried my best to document as much as possible along with pictures. I hope you find them useful. However, do use the information provided here "as-is". or the author does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, or process disclosed. Use the information at your own risk.
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