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I didn't do any additional checks because after driving it a couple more times over the past several days the battery is fine. The alternator has built its charge back up and is holding it. I think the 75% reading that morning was due to it just needing more time to charge, since it was...

My van's battery is only a year old. I forgot and left the lights on overnight so the battery didn't have enough juice to start the van yesterday. A digital voltmeter showed only 3.5 volts. Instead of jump starting it, I hooked a Schumacher SC-1200A charger to it and charged it in-vehicle...

I used the Heads Up kit from Pep Boys and the adheisive from the same company. The grey foam-backed material went on beautifully....looked great. There's just enough material in the SUV size roll to do the complete 2-piece Aerostar headliner. I was really happy with it for about a week...

My '93 3.0L did the exact same thing....hard to start, rough idle but better when warmed up. Someone on this board suggested completely removing the air cleaner box and checking the vacuum hoses beneath it. Bingo! One of them had cracked and slipped off the connector. It was the one which...

"Have you checked your key. Mine was chiming like crazy then eather Brook or josh p said check key switch." It probably is indeed the ignition switch. It's been flaky for years....sometimes chimes when the key is removed until I lightly tap on the switch, then stops. That CAN'T be right...

"Mine did that, I just unplugged the module. Only thing I miss is the headlight reminder." Thanks. I'm surprised your ammeter still worked after unplugging the module. When I pulled the fuse for MY module, it temporarily killed my ammeter. Anyway, I pulled the Warning Chime Module from a...

Yes, I'm positive it's the solid state Warning Chime Module located just above the fuse panel. I actually removed the module, let it hang down by its cable harness then covered and uncovered the holes above the small speaker while driving to verify the dinging was coming from it. Plus if I...

Have any of you longtime Aerostar sufferers I mean owners ever had your warning chime constantly dinging when it shouldn't be? Since my van had been sitting for about a week I decided to drive it today. It started normally, I buckled my seat belt and took off. The warning chime continued to...

I can't find the rule governing this.

I ended up buying a couple on Ebay for $9 shipped, and they were in excellent condition. Apparently the same ones are used on a lot of Ford and Mercury vehicles.

The function switch where I select between A/C, Vent, Floor, Defrost, etc. has been flaky but working for a few years. Now it's dead. The knob and shaft will turn but I don't feel or hear any connections being made inside the switch. Ebay has several used, supposedly working, control...

The plastic hook/clip/bracket/retainers which the free end of my visor snaps into are both broken. Other than the junkyard, is there another source for these? I found a pair listed on Ebay for $12, which seems a little high.

I put a coat of black latex paint on the cardboard to seal the fuzzy surface and hopefully get a better bond with the glue. It's drying overnight before I put one more coat on it. It should be ready to glue day after tomorrow. I doubt that it will look like a professional job. I'll just be...

Thanks, I'll pick up a flap wheel for my drill. Would a 3" wheel with 120 grit be sufficient, or is that still too coarse? And were you able to do the entire headliner with just the one wheel?

Thanks, that appears to be an exact match. You're right about the ones from China. I bought a bunch of the smaller ones for the door panels from a China Ebay seller. Very reasonably priced and they worked fine. But about 3 weeks delivery time.

Brooklyn and Josh P: Do you remember what method you used to remove the original headliner's foam backing remnants from the cardboard headliner? I've tried scraping it off with a putty knife like they've shown in some YouTube videos. Unfortunately, the headliner is actually several thin...

As for which grey......last weekend I bought the Heads-Up replacement kit from Pep Boys in LIGHT Grey. It matches the original material perfectly. I'm hoping the 9 feet of material in the roll will be enough to do both sections of the headliner.

I just checked his listings. Most of the lighter stuff has free shipping.

I've pulled the front section of my light grey headliner out. I'm ready to scrape the old lining off the board then glue the replacement material I got at Pep Boys on. The headliner board's original plastic push-in panel retainers are shot. They have a head that's 1 1/4" or 31 mm in...

Thanks....I'll accept that as gospel.

My 93 has grey interior. Should I order the medium grey, dark grey or charcoal material?

My right rear brake cylinder is leaking. I've seen some YouTube videos where they were able to (carefully) remove the cylinder on some non-Aerostars by just removing the wheel, drum and upper spring. Anyone know if there's enough clearance in the Aerostar brake assembly to pull the cylinder...

Quick After Action Report: The "Replaces Ford N801925-S" black retainers I order from China via Ebay arrived a couple of days ago. They all worked perfectly, with no hole size difference issues. Granted, their little fins may shred to pieces if I ever have to remove them but I'm thinking...

I just finished the job. I followed the Haynes directions: pulled the connector off the inertia/rollover switch, started the engine and waited a few seconds until it stalled from lack of fuel. When I pulled the lines off the filter, there was still quite a bit of fuel that shot out and then...

I'm doing an oil change myself tomorrow and thought I'd replace the fuel filter, too. I've only did that a couple of times on this Aerostar but I seem to remember pulling a connector or pushing a button behind the passenger kick panel. That was supposed to relieve the fuel pressure but I...