91 Aerostar E-4WD front differential/axle mounting bracket is broken.

[bry]

Hi, I just joined and am looking for front differential bracket and advice. The front differential mounts to a bracket. That bracket broke and the whole axle and differential assembly rotates front and back. I haven't been able to find one yet. Are they different from year to year? Any help or diagrams or correct nomenclature would be appreciated.

 

[BrooklynBay]

Welcome to this forum! Could you take a picture of this part? Are you referring to a bushing that is held in with a bolt? This vendor might have what you need: http://www.automotivepartsunlimited.com/

 

[bry]

Thanks. Basically I need all the mounts for the axle assembly on the front of my axle of my AWD aerostar. The differential dropped down onto the subframe and wore out the u-joints on the front driveshaft. When I push up on the differential I can lift it up 2 inches. There is this long piece of metal that has holes that fit over threaded posts and are connected by nuts. There are two bolts that screw into the differential. I don't have it out of the van yet to take a picture.

 

[bry]

picture of the part I am looking for

here is the part. I went to a salvage yard that had two aerostars and the brackets on those were broken too. I figured it was a pretty common thing on the all wheel drive models and hoped that somebody made new ones. I put the corner back on for the photo so that it looks more like it should.
Any help or leads would be appreciated.

 

[BrooklynBay]

Thanks for the picture! Did you contact the vendor mentioned in post # 2 or any other vendor on this site?

 

[bry]

I just contacted your recommended vendor from post #2. I haven't contacted anyone else other than local (Denver area) salvage yards. I would prefer new.

 

[BrooklynBay]

If he doesn't have what you want, then you could see if WWW.RockAuto.Com or WWW.FastPartsNetwork.Com have it.

 

[emerson]

AWD front diff brace

The bracket that bolts to the driver's side of my front diff is broken and ford doesn't carry such a thing anymore. Are there any aerostar cousins that have a similar set up? Anyone have this happen before?

 

[BrooklynBay]

Welcome to this forum! I've merged your thread with a similar thread.

 

[emerson]

I found a couple these brackets (they bolt to each other) at the wreckers today. The first one was broken and the second slightly cracked, but good enough to roll for now. Cost $40 together (I removed).

 

[bry]

Hey BrooklynBay

I finally found one out of a salvage yard in Nebraska, and it was in great shape. Thanks for your help and the leads.

 

[BrooklynBay]

Thanks for the update! How much did they charge you? It would make a nice how to thread to show how to replace these parts. Take some pictures, and make a step by step how to if possible.

 

[DoOver]

Bracket on front differential broke, causing axle shaft to seperate, loss of power

Hello, been a long time since I've been back here. I have a 1995 EAWD Aerostar totally rotted. It seems that my van is splitting in half. This has caused the engine to fall and rest on the front differential. This extra pressure has caused the bracket that attaches the front differential to the frame to break. The passenger side of the front axle has fallen and caused the short axle shaft from the front differential to the right side hub assembly to pull apart. This has caused the transfer case to send all power the the right front passenger side tire, thus stopping all motion in the vehicle.
I am going to jam a 2x4 up to hold up the front diff. and may be a piece of bailing wire.
I have bought a new axle shaft. My question is, how does the short axle shaft come out of the differential? It seems like it should just pry out. But I am having no luck in getting it to come.
Thanks,
Brian

 

[BrooklynBay]

You will need a horseshoe attachment on the end of a slap hammer. Don't lose the retaining clip on the end of the CV axle.

 

[DoOver]

Looks like I'll be trying a sledge hammer and a wood splitting wedge. Thanks

 

[eemer600]

My '97 Aerostar has the same problem with the front differential mount. I discovered the break in the mount after removing the differential. The mount is nearly impossible see with the differential in place.

I see the post about removing the axle shafts is old, but I cannot resist mentioning that these half shafts do not pull out. They are bolted on to the shafts in the differential, and the differential shafts are clipped in. You cannot remove them without removing the clips from inside the differential.

Why did I remove my front differential? I was not at home and my wife took the vehicle to a local Ford dealer to have it serviced, and they put gear oil in the differential. The factory manual specifies Dexron/Mercon. At some point the seals failed, and it does not hold any oil. So the differential is noisy and will not hold oil.

Good news is that I found one for a reasonable price, delivered, at woodfins.com. I have yet to locate the ruined rubber mount on the broken bracket though. This seems to be a weak link, so I intend to weld it and reinforce it. I will take some pics and post later.

 

[Fordsgalore4]

If this helps there a early 90 all wheel drive Aerostar at the junk yard here in LA i saw yesterday

 

[eemer600]

The junk yard is the only place you will find the axle mounting bracket, because no dealer has the part, according to Jim Coble at gaudinauto.com. He did send me a couple of good diagrams, though. I could not find a source for the rubber isolation mount, so I removed the rubber and replaced it with urethane caulking.

 

[eemer600]

Welded Repair of Aerostar front Differential Bracket

I am happy to report that I was able to affect what I think is a reliable repair to this front differential bracket. I no longer have the clunking while going into gear or changing gears. The rear end of the bracket is now very solid, and held in place with both vertical and horizontal fail safe mounts effectively joined.

I would like to post picks, but cannot due to allocation. Just so you know, I welded the two pieces of the bracket together. This made assembly a little tricky but not impossible. I guess I can post the pics on facebook. You might look there at Ernie Marks.

The shock mount is also repairable with urethane caulking. Remove all of the old damaged rubber to the fail safe mount, fill it will caulking and let it cure for several days. Make sure it is centered and flush, then let it sit.

 

[BrooklynBay]

You could upload a few pictures to a post by clicking onto the go advanced icon, then click the manage attachments icon. Photo Bucket is another option.