1994 3.0L 5 speed Aerostar to-do's & pending modifications.

[puttputt]

After purchasing this '94 three weeks ago, I've detailed a preliminary list of to-do's & modifications. First & foremost was a persistent oil leak which appeared to be the front crank seal - well. I was wrong. After drilling down to the suspected culprit, I found instead a misplaced (pushed out) pan gasket seal along the bottom edge of the timing cover. Fortunately, the gasket wasn't damaged. After seeing this, I 'd be wise to add a PVC valve replacement to the to-do list - then double check for crankcase pressure... eh?

Since it was necessary to pull the timing cover, I thought I'd go ahead and renew the timing gears & chain. They definitely needed replacing as there was more than an inch of lateral slack causing the valve timing to be about 7 degrees retarded - NOT good for MPG.

Reassembly will see a few changes. First is the elimination of the OEM fan and all A/C components, and the installation of an electric fan (heisted from dad's '97 Taurus).

After buttoning the engine back up, I'll probably focus on exhaust system modifications, then tackle the electrical quirks.

And after the flowers start blooming, I plan to replace all rear side glass with fiberglass panels - I always preferred a true cargo van, but could never locate a decent one w/5spd.

Here's the victim...

 

[JohnAerostarXLT]

I thought that van was red? Obviously not but I could've sworn the one I saw on craigslist was red. Oh well. Very clean example, though.

How many miles are on the van?

 

[BrooklynBay]

It looks like it's in very nice condition.

 

[puttputt]

I thought that van was red? Obviously not but I could've sworn the one I saw on craigslist was red. Oh well. Very clean example, though.

How many miles are on the van?

This one was on Twin Falls CL - it initially had no pics, then she later uploaded a couple. But when I tried to find the ad again, it had vanished for some reason. Nope, not red, it's actually Ford's "Medium Mocha". Has about 190k

It looks like it's in very nice condition.

Yes it is. I'm the second owner. She said she paid $16,112 and the title stated "12 miles". The clutch, fuel pump, front brakes and pwr steering pump were the only major items she had replaced. Except for the sliding door tracks, the body is tight and well cared for and the suspension appears tight. I gave $950. Not an unusual example - many Aero's here I've seen were equally nice, but more $. We don't salt hwy's here so rust issues are non existent.

 

[BrooklynBay]

Most of them where I live have severe rust along the rocker panels & sides. Just about every one of them has broken bumpers since they are very fragile. It's very rare to find a sport model with running board trim. The door panels crack, and the head liners sag near the windows. How do they control the snow if they don't salt the roads where you live?

 

[puttputt]

How do they control the snow if they don't salt the roads where you live?

Big shovel... and lots of Advel Huge blades and lots of diesel HP on the hwy's I'd move if they ever started using salt.

 

[puttputt]

Re: the sliding side door

It is sagging slightly at the front. I looked, but didn't see what vertically supports the door. The lower track bracket assy (front) is sliding on the seal - so how do I raise it 1/4"?

 

[BrooklynBay]

The lower track has a roller on a bracket to keep the door raised. Another member pointed out that there's a hidden adjustment on the center roller. I was unable to find it, but he said that it was near the latch mechanism.

 

[puttputt]

The roller shafts (both upper and lower at the front) are exposed more than they should be. So is there a snap ring or similar preventing the roller shafts from dropping down in the rollers? I guess I just need to take it apart and see what makes it tick...

Another member pointed out that there's a hidden adjustment on the center roller. I was unable to find it, but he said that it was near the latch mechanism.

At the rear (center) track? I'll look - thanks.

 

[BrooklynBay]

Take a look at this thread: http://www.explorerforum.com/forums/showthread.php?t=377780

 

[puttputt]

Thanks - good info. However, my problem seems to be at the front rollers, not the rear (center) roller. With the door opened slightly, you can see the misaligned body lines at the front. The door closes easy if I just raise it slightly by the handle, and pull it shut. But I'll check the rear roller too.

 

[puttputt]

No more in-your-face 'flying saucer' hubcaps. The rims look darker, but are not -- They are the same color as the van. Currently 215/75R15's on Ranger rims, OEM 14's still on the front - I'll replace the 14's w/matching 15's after I grind-off some more rubber. Wally had a sale on Goodyears, and I was after increased load capacity, so the 215/75's were chosen over the 70 series. I boosted my load capacity about 250 lbs, and they turned out to be a much better match for my 3.73 gearing.

 

[puttputt]

Update

After more tinkering, my fuel mileage has improved a little.

Best of 31.4 mpg hwy - 23.7 mpg city. Recent trip from Filer, Idaho, to Silver Creek, Nevada - 352 miles 13.1 gal. Overall average 26.8 MPG. First half of the trip is elevation increase from 3700 ft. to 5500 ft. and a 15 MPH avg head wind. The return leg (two days later) is, of course, downhill with 8 MPH tailwind where I achieved the 31.4 mpg. I hovered around the speed limit the entire trip. Approx 150 pound payload.

1. Replaced catalytic converters W/1-5/8" test pipe - straight section about 52" long and welded in. This is TEST mod only to confirm cat's condition, so the a new cat will be installed if the test results proves worthy.

2. Removed clutch fan and installed 13" electric.

3. Replaced timing chain.

4. All tire pressures @ 38psi.

5. Rear seats removed.

6. No tuneup or engine mods yet - still runs good with no abnormalities.

A tuneup is planned this week, and I plan to experiment with ign timing changes. Next test trip to Boise (about 250 mi round trip).

 

[BrooklynBay]

That's great mileage! Thanks for sharing your mods & test results. What was the stock MPG before the mods?

 

[puttputt]

That's great mileage! Thanks for sharing your mods & test results. What was the stock MPG before the mods?

24.3 mpg combined.

http://www.explorerforum.com/forums/showthread.php?p=3114311#post3114311