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I will say that I don't have hardly any shaking in the steering up to 70mph. Above 75 it gets a little vibration, but I rarely go much faster than that. Has anything been changed from the stock suspension? I thought I remembered yours having spacers, but I may be mistaken. How much play do...

I would check the movement on the free-wheel clutch actuator. Mine had a leaking diaphragm so it was slow to engage. If it is worse on yours, then it may be holding the clutch in an intermediate position.

I do all of the drain and add process at once with no driving between. Once the fluid color is good and the level set correctly, I don't bother with it for 50k miles.

I usually get 8-10 quarts of sp3. Drain ~2qts through hose described in the instruction. Add 2 and repeat until fluid color is a nice red like the new fluid. Then use 1-2 quarts to help set the level on the dipstick.

I would also check for a coolant leak in the valley behind the water pump.

Mine had an Autozone battery when i bought it. Worked for about another 3 years, but always gave me fits in the winter. Sometimes my car may stay parked for a couple weeks while I am away. The security system still runs and drains a little at a time as well. The DVD system and 12V ports...

Looks good on the outside, at least. Grab the FSM from my link if you haven't gotten one already. Can't help much with the OBD codes since I have not worked with that model. Not sure about OEM timing kit supplier. Someone should be able to give you the part numbers, and I think there used to...

If you already have a 03+ with the traction control, then the LSD is not really needed. The traction control functions in the same manner on trails so the LSD was dropped in later models. Toasty would be correct about the no traction/free wheel situation if it was a standard helical...

Grab the FSM from my link below and look for the sunroof calibration sequence. There is an 03 and an 05 manual that should cover everything in your vehicle.

Be sure to grab a FSM from my link if you don't already have one. Adventure Driven Designs has some upgrade skid plates available. Rocky-Road has sliders. I can also recommend Skidmark 4x4 trailer hitch plates to compensate for the departure angle. Also your 03 should have the 3.8L with...

Clicking noise might also be the U-joint in the front driveshaft. It has a grease fitting that needs to be serviced occasionally. If the bearings are bad, then it can be replaced or fixed at a local driveshaft shop.

Try to look in the valley of the engine under the intake manifold for coolant leaks. A bad o-ring in the back of the water pump housing was the source of my overheating issues for about a year. It would dry before reaching pavement, but caused air bubbles and coolant loss. I also had to clean...

Very glad you caught the timing belt. That would definitely have shut down the whole project. Reliable is all you need for an expedition. Mine has been stock except for a trailer hitch plate and some additional lights. I still take it out every chance I get to explore dirt roads.

Make sure you grab the relevant FSMs from the link below. They will give you all the information you could ever need when you start working on it. I recommend getting all of the Gen 3 manuals.

The blinking lights can be anything from a bad solenoid or vacuum line to just having different brand tires at the corners. The system has a check for each wheel speed before disengaging the center differential. Having different tires can cause these numbers to not always align for it to begin...

I cannot confirm if it is sealed or not based on the picture, but I have always run LSD 90 oil. The manuals spec 1.6L of GL-5 gear oil SAE 90, but do not mention friction additives.

I swapped a 4.3 hybrid lsd (hyblid on the label) into my 05. Everything works as expected, even traction control. Been running it for 40k miles.

You are correct in using the OEM fluid for your LSD diff. The redline fluid will not work with the hybrid system. Mitsubishi's Hybrid LSD has a torsen style gear system, but uses a small clutch pack as well. Gear systems are stronger than clutches, but they need some torque on both wheels to...

The solenoid is on the left side (passenger) of the engine bay mounted to the inner wheel well. Also double check the vacuum lines for leaks and that the actuator is not having a problem.

Looks very good. Congrats on the 4.9 LSD. Those are getting difficult to find.