How to: Modify taillights to swap onto an Aerostar.

[BrooklynBay]

As these vans are aging, parts are getting harder to find, and a need to improvise comes about. This thread will show you how to modify a passenger's side taillight which is made for a non rear wiper van into a rear wiper design.

Here's a side by side comparison of both taillights:

The light on the left is for a non rear wiper equipped Aerostar. The light on the right is for a rear wiper equipped Aerostar. The best way to make an accurate cut is by using a template. A template is made from the cut taillight:

The template is transferred & taped onto the other taillight, and is ready to be cut with a multi-tool:

The foam insulation on the back needs to be trimmed:

The taillight on the left is the finished product:

The modified taillight is now ready to be installed.

 

[BrooklynBay]

The 1996 version taillight has different sockets, and is not easily interchangeable with other years. It's possible to modify it, so here's a side by side comparison between the 1995 & 1996:

The 1995 Aerostar taillight is on the left, and the 1996 taillight is on the right.