I've owned 2 Aerostars previously, a 1991 that was a dealer demonstrator, bought it from the dealer in December of 1991. Extended, 3.0L XLT. It was a good vehicle, other than the AC. The AC had multiple problems, and cost me several thousand dollars over the course of ownership. Finally the ex-wife had an offset head on collision with a dump truck while under the influence (one of the many steps she took in order to become my ex). She suffered only minor injuries, but it basically shaved off 6 inches of the drivers side from front bumper to rear bumper. Totaled, naturally My Second Aerostar is a 1995 I bought in 2005 with about 125,000 miles on it. Fabulous vehicle. Extended XLT with a 4.0L. I've probably put less than $500 in repairs on it, and I bought it on ebay for about $2400. 3 grand for 12 years and 90,000 miles, it's been a wonderful vehicle. It has developed leaks in the rear that drip onto the wheel well area in the back. The last time I replaced the windshield, the tech told me that this would probably be the last time the windshield would be replaceable due to the metal frame rusting out. The engine, transmission, and AC are all still perfect. But.. it was time to find it's successor. I live in Mobile Alabama. I searched for a low-milage Aerostar, and found a 1991 in Jackson, MS, 190 or so miles away. It met my want list: Extended, 4.0L, relatively low mileage at 109,000. The interior, except for some slight stains and a small tear on the drivers side, looked like new. Garage kept, the exterior was flawless, except for broken bumper covers. No big deal. Test drove it, checked the fluids, everything looked good. I bought it for $2400. It drove beautifully for the first 175 miles of the 190 mile trip home. On the way home, my brother-in-law was following me back home. He called me and said he noticed some smoke coming from the center underside center area of the vehicle. I had noticed some grime of some kind accumulating on the rear window during the second half or so of the drive home, but attributed it to road grime from the thundershowers we had been driving through. At the last red light before I got home, I noticed some white smoke, and the transmission hesitated before going into gear to pull away from the light. It was 1/4-1/2 mile to my home, and I got the van home. I checked the trans fluid and it was barely showing on the dipstick. I suspect the smoke was due to the trans fluid leaking onto or blowing onto the exhaust system. I added all the fluid I had at home, a little over a quart, and it shifted better, but it was still not full. But - the fluid showing on the dipstick did not appear burned, which I hope is a good sign. The previous owner, an old man who has since passed away (I bought it from an heir to his estate), had pretty complete service records. As I reviewed them (something I should have done before I agreed to purchase the van, but I was seduced by it's beautiful condition). The van has had multiple major AC repairs, major transmission repair, upper control arm bushings replaced twice (remember, this is a 109,000 mile vehicle. My 1995 with 215,000 has just worn out it's first set of upper control arm bushings), 3 or 4 front brake pad replacements, and some engine repairs (head gasket if memory serves). I've got a very good transmission guy who is very reasonable, and I'm taking the van to him on Monday to evaluate the Transmission situation. After that, I may take it to my mechanic (the guy who I take the stuff I can't fix to) and have him give it the once over. Two questions for the forum: 1) I had a bad experience with my first 1991 Aerostar with respect to the AC. This one has some AC repair history. My 95 has never had an issue with the AC. Was the AC system in 1991 problematic? Did Ford get it straightened out by 1995? Or is it just my first and current 1991 Aerostars having isolated AC issues (made on a Monday maybe?) 2) Given the information I have outlined, if you were in my position, would you keep this vehicle, or would you correct the obvious problems and get rid of it before the next one pops up, and go looking for another Aerostar? I'm 59 years old, and the extended Aerostar serves my purposes well. I'd like to find one with around 100k miles or less. Since it is not my primary vehicle, and I'll drive it 4000-7000 miles a year, if I can find a good one, it should be the last one I'll ever need, assuming that it makes it to 215,000 miles like my 1995 Aerostar has. I look forward to the forums response. I'll post pictures of the van this weekend. Thanks.