We recently purchased a 2003 Eddie Bauer Explorer.
Whilst driving with speed control engaged, It felt as though the brakes were being applied.
I also subscribe to an Expedition news group and the following TSB was posted.
Does Ford pay for the TSB repair or do I have to stand it.???
Ride safe
Barry
TSB 04-24-20
12/13/04LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING
SENSATION, OR VIBRATION DURING LOW SPEED
TURNING MANEUVERS
FORD:
2002-2005 Crown Victoria, Mustang, Explorer2003-2005 Expedition
2004-2005 F-150LINCOLN:
2002-2005 Town Car2003-2005 Navigator
MERCURY:
2002-2005 Grand Marquis, MountaineerThis article supersedes TSB 04-17-5 to update the model year and vehicle line coverage.
ISSUE
Some 2003-2005 Expedition/Navigator, 2004-2005 F-150 vehicles equipped with a 9.75" or 8.8" limited slip rear axle, and 2002-2005 Explorer 4dr, Mountaineer, Crown Victoria, Grand Marquis, Town Car, and Mustang vehicles equipped with 8.8" limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4x4 vehicles, the sensation may appear to be originating from the front axle or the steering gear.
ACTION
First verify the condition. On 4x4 trucks ensure that the vehicle is in 2WD, to isolate the rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack.
SERVICE PROCEDURE
CAUTION INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY.
Order and install the appropriate clutch pack, follow the installation instruction sheet included in the service kit.
^ 3L1Z-4947-AB (9.75" limited slip)
^ 3L1Z-4947-BC (8.8" limited slip)
NOTE INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO FOLLOW THE INSTALLATION INSTRUCTION SHEET INCLUDED IN THE SERVICE KIT.
INSTALLATION TIPS
^ The clutch packs in this service kit DO NOT need to be shimmed. The clutch pack contains a pre-measured shim.
^ Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the service kit).
^ Soak the new clutch packs in Friction Modifier XL-3 (NOT XL-7) for fifteen (15) minutes prior to installation.
^ For IRS axle, Halfshaft Seal Protector 205-506 (included in the 2002 Explorer/Mountaineer Essential Tool Kit) must be used when removing the halfshafts to protect against seal damage, which may result in leaks.
^ Refill axles with 4 oz. Friction Modifier (XL-3) and the necessary amount of Rear Axle Lubricant XY-75W140-QL, regardless of the axle lubricant system originally used in the axle. Fill to capacity recommended in the Workshop Manual.
NOTE AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF XY75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA). ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT SIDE AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE LABEL.