So last time I changed the brakes and rotors, I was unable to get the rear brake wear sensor to plug in (not on the caliper/sensor side, on the plug side). I checked to make sure the plug was not damaged on the sensor, and it was okay. This leads me to believe that the other end of the plug is damaged.

Has anybody experienced this issue or had to replace this piece before? The sensor seems to go 80% of the way in, but won't snap into place. It's not in the easiest spot in terms of visibility.

 

I was working on the front suspension last night, but believe the rear sensor wiring is the same: there is a plastic "box" that protects the connection between the sensor and the rest of the wiring loom. If you prop the box open and remove the harness plug, you should be able to press the two together all the way.

Lastly, as long as the brake light is out and the connection is good and water proof, you should be are all set. Put a layer of duct tape over it, if you want to be 2x sure that it wont separate.

a

 

Are you sure you had the plug aligned right? If it were rotated wrong you'd get just that behaviour. It only fits one way and there are tabs to stop it going together the other way.

 

I can feel the plug go into the correct slots, but not far enough into them. Its like there is something bent or stuck in there. When i removed the plug, it came off way too easily.

 

Put the rear end on the jacks, remove both rear wheels, and compare sides: right vs. left.
That should tell you all you need to know about plug alignment, fitment, and condition.

Is the brake wear light ON or OFF?
If ON, it is possible you had bent one of the leads inside the plugs, and the bent wire is preventing the plug on the damaged side from fully seating.

a

 

There is no sensor on the left rear. The brake light is ON because the plug won't connect and thus it reads as a broken loop (same as if the sensor were worn down).

 

Duahhhh, I knew that. Need more coffee

I meant compare the plugs between the front and rear brake wear sensors. The front one is on the driver side, I believe.

HTH,
a

 

It still sounds like the plug needs to be rotated. Try rotating it 180° and see what happens. If you can see the plug you can align it with the pins. There are two pins and they're offset.