New to the forum, and new to me 1997 Aerostar.

[tucson_sailors]

Been searching the threads, and can't find the reference I saw earlier, so throwing it out the group, and hoping my "newbie-karma" will suffice for lack of better searching skills.

1. On my new to me 1997 XLT, the front A/C seems to be fairly weak. Had the shop test the resistor and motor, and they don't see anything wrong. Is it usual to have pretty anemic CFM through the front ducting? The rear A/C blower sounds like a hamster on speed, wondering if you can swap the rear and front blower motors. System was evacuated and charged to 54 oz charge per the info on the site - thanks to whomever posted the capacity chart.

2. Does anyone know if there is an all-aluminum 3 core radiator made that will fit the 4.0? I've found reference to earlier years possibily having a Silla (local radiator shop about gagged when I mentioned that, they've had lots of problems with build quality) 3 core, but not for the 1997 4.0. I thought somone had mentioned they had one, but I can't recall if that was the 1997 or not.

Otherwise, putting this one back together. Gold and cream with the tan interior. Missing one captains chair, and the door pockets need new elastic, but hey, what do you expect from something made in 1996 and still on the road?!

Glenn in Tucson

 

[BrooklynBay]

Welcome to this forum! Check these sites:
WWW.AutoCoolRadiators.Com
WWW.RadiatorBarn.Com
WWW.RockAuto.Com
WWW.TousleyFordParts.Com
WWW.Autozone.Com

 

[Jose A.]

Congratulations!

you can find the cream-color elastic at Joann Fabrics, get two packets, one for each front door. $1.59 ea. and if you look at the sunday paper they have 40% off coupons!
(same for headliner fabric if you need to replace it)

the front fan speed is never high enough on max speed in summer. I haven't tested if the rear fan is the same as the front, although I think they are the same, but for some reason the rear fan sounds more powerful than the front. I do agree the front could use more air pressure. you might check at Autozone to see if they have different part numbers. Unless there is some other part, like a resistor that somehow controls the max speed....

the normal radiator is good enough, in any case you might spend the money on a better Condenser for the a/c.

I'm on my third Aerostar since 1986, just bought my third last May. They are reliable, comfortable, and rear wheel drive. (I don't like front wheel drive anything!). I removed and stored the rear seats, I'm a part-time musician and use the Aerostar to carry my equipment to the job.

 

[tucson_sailors]

Thanks!

Will follow up on the suggestions from both replies. If I do happen to find a faster fan for the front, will be sure to post how I did it. I'm thinking a resistor block swap from another ford, or maybe an electrical shop can find me a compatible motor that has a higher RPM rating.

Any reason for a better condenser? From all I've read on the forum the 1997 a/c setup was the best of the bunch in terms of reliability, compared to earlier years. I've got a local A/C parts shop that I can purchase from if you have a suggestion for a particular model/maker that is better than OEM.

Glenn

 

[Jose A.]

Any reason for a better condenser? From all I've read on the forum the 1997 a/c setup was the best of the bunch in terms of reliability, compared to earlier years. I've got a local A/C parts shop that I can purchase from if you have a suggestion for a particular model/maker that is better than OEM. Glenn

I'm new to my '97 and I'm still learning about it. But I'm involved with Jaguars and Aerostars. Back when I had the '92 I installed a multi-flow condenser, also used in Jags and retrofit Jaguar a/c.

I purchased it from a crash parts company called Keystone Industries back around 2000 when I lived in Tennessee. It did improve the "I'm freezing factor" considerably. Maybe the '97 has one of those?, I don't know.

if you want to learn about multi-flow condensers, check this Jaguar link:
(sorry I don't have a link for Ford Aerostar multi-flow condensers).

http://www.retroair.com/jaguarairconditioning/mkiis420lhdrhd.html

yes, if you find a more powerful fan for the front, let me know, all my 3 Aerostars have always had anemic front fans.

 

[tucson_sailors]

Upgraded condenser

if you want to learn about multi-flow condensers, check this Jaguar link:
(sorry I don't have a link for Ford Aerostar multi-flow condensers).

http://www.retroair.com/jaguarairconditioning/mkiis420lhdrhd.html

yes, if you find a more powerful fan for the front, let me know, all my 3 Aerostars have always had anemic front fans.

Will have to look into that for multiple reasons. I have a 1984 XJ6 black/tan "lump" that has a chevy 350 in it, where the A-6 was never remounted. Have to install a sanden or something similar so I'm quite interested in the vintage jag air aspect as well. Vintage air in Florida does make assemblies for it, but have to figure out if I'm top or bottom, passenger or driver mounting the compressor so I can figure out hose lengths.

Good info, will keep posted on what I find out about a possibly more hoss fan for the front venting.

Glenn

 

[Jose A.]

interesting, another XJ - Aerostar owner !!

you might contact Rock Browning at Retro Air, (the link I gave you, he's in Texas); there is a new, redesigned Harrison A6 compressor available and he sells them, I'm planning on getting one too. It is lighter and more efficient.

I removed the entire interior paneling in my Aerostar because I'm rewiring the speakers to get away from the common ground Ford wiring, so the rear a/c and fan are exposed, and I can see the mounting plate is identical to the front. I'm going to try and exchange the fans and see what happens. Removing the rear is easy, it's the front that it's a pita.

 

[tucson_sailors]

Updates - tracing the front A/C issues

Curious-er, and curious-er.

Found the max door underneath the airbox. Flap is visible at the front (rear if you were at the front of the vehicle) just underneath the airbox behind the glovebox when the unit is on normal - airbox under the glove box is cool to the touch and cold air is coming out of the vents. The question is - should I be *able* to see that flap?

On normal I can change from 1/2/3 on fan speed and there is an increase. So the resistor should be ok. A/C lines are cold.

Move to max a/c, and the flap moves towards the front of the vehicle - slowly, not the "thump" I've always experienced with other cars. I noticed that I was getting a mix of cold air from the system, as well as warmer air coming out directly through the hole in the ducting (oval shaped, about 6 to 8 inches through which I can see the flap).

Checked the connectors at the resistor block and the connector to the fan for corrosion, etc. Nothing obvious.

Have seen some other discussions where they have blocked the fresh air intake underneath the grill on the windshield area. I live in AZ, about 2 inches from the sun so using normal a/c is not an option most of the year, so if it only works on max/recirc, thats not a problem.

If Brooklyn or Jose want to comment on other steps to check, advice appreciated. Also thinking about getting the Ford Service manual for the 1997 from that big online auction site - they have it on dvd/cd for $10.00, anyone have a copy and have any good/bad to say about it? Already have the haynes, but need something with better exploded diagrams.

Glenn in Tucson

 

[Jose A.]

I would not block the air intake at the cowl, you need it for the VENT position of the switch and the NORMAL a/c position.

I know there are issues with that flap door, it either breaks or becomes "lazy", there is a vacuum actuator and the vacuum lines under the front speakers panel in the passenger side near the right front speaker, (the panel is a pain to remove and you need a phillips bit with a socket and small ratcket and small wrench to remove it due to the glass angle).

you might check that vacuum actuator, it could be the cause of the slow door. Also, it could be misconnected vacuum lines at the rear of the Switch itself? (those switches are known to go crazy, especially since you say you are getting a mix of cold and warm air).

I'm looking for the '97 Aerostar Factory Shop Manual CD (not Haynes or Chilton, those are a joke), where did you see it for sale?

 

[tucson_sailors]

Service DVD and ongoing a/c

Found on the big online auction site. Should have it next week, if its not some sort of flea-bay scam, I'll post the vendor so he can get some other orders.

Update - search for "goodyou10" on e-bay, thats the vendor that sold me the Service DVD/CD. Installed on my Win7 setup with no issues. Seems to cover a multitude of vehicles/years, make sure you get one appropriate for your year - email the seller to make sure.

I'll hold off on blocking the vent, will check the switch. Hoping that the service cd/dvd will have the exploded diagrams - would help in trying to figure out all the ducting on the a/c.

Did have an idea - the rear a/c has a ducting that goes along the roofline to point at the rear passengers. I don't as a general rule have any, so thinking about doing some bodge engineering and moving the vents to the bottom, so they can be directed at the front passengers as well as the rear. Its just thermoplastic as far as I can see without any servos, or electronic stuff, so should be able to dremel and fit cover plates so that it can be reversed if I ever feel the need.

Glenn in Tucson

 

[Jose A.]

good idea! just cover/seal the rear-facing square holes for the vents duct with fiberglass, and cut new ones, then just reverse the finisher vent panel as best as possible, although one side of the finishing vent panel is shaped different than the other.

I would direct the vents to the front.