However, if you're determined to tackle it yourself, here's a general overview of the process. This is not a comprehensive guide, and you should supplement it with a repair manual specific to your vehicle's year and model:
1. Diagnosis:
* Identify the problem: Determine precisely what's wrong with your LSD. Is it chattering, making noise, locking up, or exhibiting other symptoms? Pinpointing the issue is crucial for effective repair.
* Check the fluid: Low or contaminated differential fluid is a common cause of LSD problems. Inspect the fluid; if it's dark, metallic, or smells burnt, it needs replacing. This might solve the problem without a major overhaul.
2. Preparation:
* Safety first: Use jack stands, disconnect the battery, and wear appropriate safety gear.
* Gather tools and parts: You'll need a variety of tools, including:
* Jack and jack stands
* Wheel chocks
* Torque wrench
* Differential carrier bearing removal tool (often specialized)
* Axle nut socket
* Various sockets and wrenches
* Drain pan
* New differential fluid (the correct type and quantity for your Explorer)
* Possibly new differential components (depending on the damage): clutches, plates, shims, seals, bearings.
* Consult a repair manual: A factory service manual or a reputable aftermarket manual is essential. It will provide detailed instructions, torque specifications, and diagrams specific to your 2003 Ford Explorer.
3. Removal and Disassembly:
* Remove the driveshafts: Disconnect the driveshafts from the differential.
* Lower the differential: Carefully lower the differential from the vehicle. This often involves removing the differential mounting bolts and possibly the control arms.
* Disassemble the differential: This involves carefully removing the carrier, gears, and the limited-slip components. This step is highly complex and requires careful attention to detail. Pay close attention to the order and location of components to ensure proper reassembly.
4. Repair/Replacement:
* Inspect components: Carefully inspect all components for wear, damage, or breakage.
* Replace worn parts: Replace any damaged or worn parts, including clutches, plates, shims, seals, and bearings.
* Clean and lubricate: Clean all components thoroughly and apply fresh lubricant as specified in your repair manual.
5. Reassembly:
* Reassemble the differential: Carefully reassemble the differential in the reverse order of disassembly. Pay close attention to the correct placement and adjustment of shims to maintain proper gear mesh.
* Install the differential: Carefully install the differential back into the vehicle.
* Reinstall driveshafts: Reconnect the driveshafts.
* Refill with fluid: Fill the differential with the correct type and amount of fluid.
6. Testing:
* Test drive: Test drive the vehicle and carefully listen for any unusual noises.
* Check for leaks: Inspect for any leaks around the differential.
Important Considerations:
* Limited-slip type: There are different types of limited-slip differentials (e.g., Torsen, clutch-type). The repair procedure will vary depending on the type of LSD in your Explorer.
* Shimming: Proper shimming is crucial for correct gear mesh and is a critical aspect of differential setup. Incorrect shimming can lead to premature wear and damage. Often a dial indicator is used to measure mesh.
* Professional help: If you're unsure about any step of the process, seek professional help. A poorly repaired differential can lead to serious damage to your vehicle.
This is a highly simplified overview. A detailed, step-by-step guide with diagrams and torque specifications is absolutely necessary to properly repair a limited-slip differential. Again, if you're not experienced with this type of repair, taking your Explorer to a qualified mechanic is strongly recommended.
