Interesting. When you clean it, is there some sort of debris or forien material on it? Seems like it should stay pretty clean. Just curious.
You know, one thing which crossed my mind - there is a specified distance or gap between the sensor and the exciter ring (mounted on the ring gear). I wonder if the vehicles which have problems were assembled with a loose tollerance here. Might be worth while next time the rear diff cover is off to try to verify that the gap is in spec, if there is enough room to measure it. My '98 manual lists the correct gap as .005" - .050".
The 1st 3 times there was some amount of small metal buildup on it, from normal wear, this past weekend when I pulled it it was perfectly clean.
Im not sure if its a sensor problem or not this time, it was on for an hour and a half ride to Boston, all the way, even when I pulled over 2 times to shut the engine and restart it, then all the way home, after being there for 2 hours it didnt come on at all. I wont be driving it much now that winter is coming but I wanted to at least pull it and check it while it was on my mind the other day.
Thanks everyone. I pulled the sensor and cleaned it but that didn't help. Checked with all the parts stores but it seems that it's factory or nothing. Got the part today and put it in and everything works great.