Crankshaft Position Sensor

This procedure covers the removal and replacement of the crankshaft position sensor on the 5.9L Cummins diesel engine, a common repair for no-start or rough running conditions.

Warnings

Tools required

Parts

• Crankshaft position sensor × 1 — Mopar 5080217AB or equivalent OEM
• Crankshaft position sensor O-ring seal × 1 — Usually included with sensor

Preparation

1. Park vehicle on level ground and apply parking brake
2. Disconnect both negative battery cables from the dual batteries
3. Allow engine to cool completely if recently operated
4. Gather all tools and replacement parts before beginning

Procedure

1. 1

   Locate the crankshaft position sensor
   The crankshaft position sensor location varies by year. On 1998.5-2007 24-valve engines it is mounted on the passenger side of the engine near the gear/timing case housing. On earlier 12-valve engines it may be located near the bellhousing area. Verify the exact location for your specific engine before proceeding; access from underneath may improve visibility and reach. It reads a target/tone wheel on the crankshaft drive train.
2. 2

   Disconnect the electrical connector
   Locate the electrical connector on the sensor harness. Press the connector release tab and carefully pull the connector straight off the sensor. If the connector is difficult to remove, use a small flathead screwdriver to carefully assist the release tab while pulling gently. Inspect the connector pins for corrosion or damage.
3. 3

   Clean the sensor mounting area
   Use a wire brush or shop towel to remove any loose dirt, oil, or debris from around the sensor mounting bolt and surrounding bellhousing area. This prevents contamination from entering the bellhousing when the sensor is removed.
4. 4

   Remove the sensor mounting bolt
   Remove the single bolt securing the crankshaft position sensor to its mounting on the engine, using the appropriately sized socket and extension (verify fastener size against factory documentation). Keep the bolt as it will be reused unless damaged or corroded. Note the bolt length and position for reinstallation.
   Torque spec

   Crankshaft Position Sensor10 Nm (7 lb-ft)
5. 5

   Extract the sensor from the bellhousing
   Carefully pull the sensor straight out from the bellhousing bore. The sensor may be tight due to the O-ring seal. Use a gentle twisting motion while pulling if needed, but do not pry against the aluminum bellhousing. If severely stuck, spray penetrating oil around the sensor body and wait several minutes before attempting removal again.
6. 6

   Inspect the sensor bore and flywheel
   With the sensor removed, inspect the bore in the bellhousing for any debris, metal shavings, or damage. Clean the bore with a shop towel. If possible, shine a light into the bellhousing to visually inspect the flywheel/flexplate ring gear teeth for damage or missing teeth, which could cause sensor problems even with a new sensor.
7. 7

   Prepare the new sensor
   Remove the new crankshaft position sensor from its packaging. Verify it includes a new O-ring seal installed on the sensor body. If the O-ring is not pre-installed, carefully install it in the groove on the sensor body. Do not lubricate the O-ring with oil or grease; install it dry to prevent it from slipping out of position.
8. 8

   Install the new sensor
   Carefully insert the new sensor straight into the bellhousing bore, ensuring the O-ring does not roll or become pinched. Push the sensor in firmly by hand until it is fully seated against the bellhousing face. The sensor should slide in smoothly; if excessive force is required, remove it and check for O-ring misalignment or debris in the bore.
9. 9

   Install and torque the sensor mounting bolt
   Thread the mounting bolt in by hand to ensure it is not cross-threaded. Once hand-tight, use a torque wrench to tighten the bolt to specification. Do not overtighten, as this can crack the sensor housing or strip the aluminum bellhousing threads.
   Torque spec

   Crankshaft Position Sensor10 Nm (7 lb-ft)
10. 10

    Reconnect the electrical connector
    Clean the sensor electrical terminals and connector pins with electrical contact cleaner if available. Align the connector with the sensor terminals and push firmly until you hear and feel a positive click, indicating the connector lock has engaged. Gently tug on the connector to verify it is securely locked.
11. 11

    Reconnect battery and test
    Reconnect both negative battery cables to the dual batteries. Turn the ignition key to the ON position without cranking the engine. On OBD2-equipped models (1996 and later) the malfunction indicator lamp should illuminate briefly and then extinguish, and a compatible scan tool can be used to verify the crankshaft position sensor signal. Earlier pre-OBD2 models will not provide this data. Start the engine and verify it runs smoothly without misfires or rough idle.

Reassembly

1. Ensure the sensor mounting bolt is torqued to specification to prevent sensor movement or vibration
2. Verify the electrical connector is fully locked and sealed to prevent moisture intrusion
3. Route the sensor harness away from heat sources and moving components

Verification

• Start the engine and verify smooth idle with no misfires or stalling
• Check for diagnostic trouble codes using a scan tool; there should be no crankshaft position sensor codes present
• Verify the engine accelerates smoothly and returns to idle normally
• Take the vehicle for a short test drive to confirm normal operation under load
• Recheck for any codes after the test drive to ensure the repair resolved the issue

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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