Repairs on my 1996 Aerostar.

[JohnAerostarXLT]

Today was a big day for my little van, heh heh. I bought new power steering pump, new turn signal switch (more on that below) and a filter/pan gasket kit (along with Synthetic ATF). Tomorrow, I'll get the tires and Explorer wheels put on (the guy wasn't home today). I also bought the correct lug nuts to install the new wheels.

It took three tries but I finally have a functioning multifunction switch. First, they sold me the wrong one. Second, the correct one worked as far as the wipers but the signals and hazards didn't work. Finally, the third one works perfectly and I couldn't be happier.

I'll continue to update this thread with the repairs I'm making to the van.

Here is the new MFS installed:

 

[BrooklynBay]

Was the connecting plug the same on all 3 switches? What about the part numbers?

 

[JohnAerostarXLT]

Was the connecting plug the same on all 3 switches? What about the part numbers?

The first switch, no, it was not the same. The "bottom" plug was and fit perfectly, but the top plug was different. The second switch plugged in correctly but was defective.Only the wipers worked, not the turn signals and hazards. I'm certainly glad I checked it's functions before I bolted everything back together.

I didn't check Ford part numbers as I was buying the switch from AutoZone, not Ford.

 

[BrooklynBay]

Was it made by Wells, Kem, Dorman or some other brand? Did you take any pictures while replacing it?

 

[JohnAerostarXLT]

No, I forgot to take pics of the install. It was AutoZone's Duralast brand.

 

[JohnAerostarXLT]

Like momma always said: If it aint one thing, its another!

Now my water pump is leaking like a siv. I bought a new one from Autozone (lifetime warranty) for $63 and am going to pay a local shade-tree to replace it and power steering pump tomorrow. Let's hope all goes well and I manage to stop spending money before my trip!


I am glad this happened today instead of on the road during the trip!

 

[JohnAerostarXLT]

Went over and took a look at the van, looks like he's 90% done with it (he wasn't home). The new pumps are in place but the fan, fan shroud, and misc. plastic air intake pieces were laying near by, waiting to be installed. Let's hope these replacement parts fix the leaks.

 

[BrooklynBay]

Which brand is the gasket? The reason that I'm asking is because a number of years ago I replaced the timing chain & water pump in my 1989 van, and three months later the paper gasket blew out on the highway. The original gasket was good for years. What kind of gasket adhesive was used?

 

[JohnAerostarXLT]

Which brand is the gasket? The reason that I'm asking is because a number of years ago I replaced the timing chain & water pump in my 1989 van, and three months later the paper gasket blew out on the highway. The original gasket was good for years. What kind of gasket adhesive was used?

It wasn't a paper gasket, it was rubber-looking (I never actually took it out of the sealed plastic to examine it).

I got the van back late last night, and the power steering is still leaking a bit, but not as bad as before. Water pump is installed and no leaks from it.

I took the van on a 50 mile trip to return the core pump and pulley puller and it did great. Now, if I can just get the tire guy to be home long enough to change out my tires, that'll be the next thing going on.

I wanted to change the trans fluid today but it's raining. Oh well, perhaps next week.

 

[JohnAerostarXLT]

Got my tires today, got two of the wheels put on. As mentioned previously, I will end up needing spacers to make the front work. The tire guys really liked my van, lol. "Man, that thing runs good! I like that little van!" It was nice to hear a few compliments on it, especially since I've spent so much money fixing it up. Love my van!

Ok, here is the first pic of the new wheel(s) installed:

 

[BrooklynBay]

You have a solid red taillight which was only used on the 1997 model. Are you sure that it's a 1996?

 

[JohnAerostarXLT]

You have a solid red taillight which was only used on the 1997 model. Are you sure that it's a 1996?

Yeah man, you don't remember my first few posts here? I mentioned adding "custom tail lamps", and that's what I meant. I drilled another hole for the turn signal plug to go in and now I have the solid-red look but with separate brake, signal, and reverse lamps (in that order).

Anyway, the front wheels still wont work, even with spacers. They still rub enough that I can't turn the wheel by hand with it suspended off the ground. So, my next step is to go with lower profile tires for the front. That's my only hope.

 

[JohnAerostarXLT]

Update: Today I swapped the front tires for some 195-55-16 Goodyear Eagles. They fit, so now my van has matching wheels again! I tried to upload a pic to tinypic.com but it wouldn't work so I'll try again tomorrow.

I was doing the transmission fluid/filter change today and figured out that I had the wrong filter (didn't check the pan gasket). I returned it to Autozone and they ended up selling me a filter/pan gasket kit for a 1995 Aerostar. So, my van is either an early build and got one of the last '95 transmissions or it's been swapped out at some point. Either way, I got the service done and then the van proceeded to scare the crap out of me.

I finished the service and took the van for a test drive. My "O/D OFF" light started flashing. My heart sank like the Titanic. I got home and shut it off and it was a little low on fluid. I topped it off and drove it again, this time no flashing light and it performed flawlessly. Whew!

 

[BrooklynBay]

The 1995 had the A4LD, and the 1996 had the 4R44E. They are two different types of transmissions with different computer systems. 1995 had OBD-I/EEC-IV, and 1996 had EEC-V.

 

[JohnAerostarXLT]

The 1995 had the A4LD, and the 1996 had the 4R44E. They are two different types of transmissions with different computer systems. 1995 had OBD-I/EEC-IV, and 1996 had EEC-V.

Mine has to have some version of the 4R44E since it has electronic O/D lockout. I do have an EEC-V port as well.

Oh well, anyway, here's a pic of the van with the wheels installed:

 

[BrooklynBay]

The wheels look like they fit very well.

 

[JohnAerostarXLT]

I got the oil change done on it. Its a little early but I wanted to be fully prepared for the trip. I am so happy with the van, I can't wait to take it on the trip.

Speaking of which, I should be leaving Tuesday.

 

[Icuff4cash]

How many quarts did it take for a filter change. I was going to add synthetic for the change. I have a oil cooler and I can't decide to pull a hose to flush everything

 

[Adam_tinkerer]

Sharp! What year Explorer rims are those, and what size tires on the rear?