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Ford Ford Aerostar

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Ford Aerostar: A Comprehensive Guide

The Ford Aerostar, produced from 1986 to 1997, was Ford's compact minivan offering, filling a niche between the larger, full-size vans and the smaller cars of the time. Designed as a versatile vehicle for families and small businesses alike, the Aerostar offered a blend of passenger comfort, cargo capacity, and truck-like durability. Its unique styling, featuring a long wheelbase and sloped front end, made it instantly recognizable. While not a sales leader like the Chrysler minivans of the era, the Aerostar carved out a dedicated following for its ruggedness and utility.

Generations

First Generation (1986-1997)

The Aerostar only saw one generation during its production run, but underwent several significant updates and changes over the years.

  • 1986-1988: Initial Launch

    The first Aerostars featured a rear-wheel-drive configuration with a choice of a 2.3L inline-four engine or a 2.8L V6 (later replaced by a 3.0L V6). The styling was consistent, with a rectangular headlight setup and a relatively simple interior.

  • 1989-1992: Mid-Cycle Refresh

    This period brought significant improvements, most notably the introduction of the 4.0L Cologne V6 engine. This engine provided a substantial power boost. All-wheel-drive (AWD) was also made available, further enhancing the Aerostar's appeal, especially in colder climates. Minor styling updates included revised taillights and interior trim. ABS (Anti-lock Braking System) also became an option during these years.

  • 1993-1997: Final Years

    The Aerostar's final years saw minor refinements, including updated interior materials and trim options. The focus shifted towards improving comfort and refinement as newer minivan designs from competitors emerged. Safety features were subtly improved, but the fundamental platform remained largely unchanged. Production ceased in 1997, replaced by the more modern and front-wheel-drive Windstar minivan.

Reliability & Common Issues

The Aerostar, while generally considered reliable for its time, does have some common issues potential buyers should be aware of. These issues are largely related to its age and the mileage many surviving examples have accumulated.

  • Engine Issues:
    • 4.0L V6 Head Gasket Failures: The 4.0L V6, while powerful, is prone to head gasket failures, particularly on higher-mileage examples. Symptoms include coolant loss, overheating, and white smoke from the exhaust. Repairing this can be costly.
    • 3.0L V6 Oil Leaks: The 3.0L Vulcan V6 is generally reliable, but prone to oil leaks, especially around the valve covers and rear main seal. Regular oil level checks are crucial.
    • 2.3L Inline-Four Issues: The 2.3L is less powerful and can feel strained in the Aerostar's weight. Common issues include ignition problems and vacuum leaks.
  • Transmission Issues:
    • A4LD Transmission Problems: The A4LD automatic transmission (used with the 2.3L and early 3.0L engines) is known for being somewhat fragile and prone to slippage and hard shifting, especially with age and neglected maintenance.
    • A4LD Upgrade (A4LD to 4R44E): Some owners upgrade the A4LD transmission to a 4R44E which is essentially a redesigned A4LD with improvements.
    • A4LD Upgrade (A4LD to 4R55E): Some owners upgrade the A4LD transmission to a 4R55E which is essentially a redesigned A4LD with improvements.
    • A4LD Upgrade (A4LD to 5R55E): Some owners upgrade the A4LD transmission to a 5R55E which is essentially a redesigned A4LD with improvements.
    • A4LD Upgrade (A4LD to Ford C3): Some owners upgrade the A4LD transmission to a Ford C3 which is a sturdy alternative.
    • A4LD Upgrade (A4LD to Ford C4): Some owners upgrade the A4LD transmission to a Ford C4 which is a sturdy alternative.
    • A4LD Upgrade (A4LD to Ford C5): Some owners upgrade the A4LD transmission to a Ford C5 which is a sturdy alternative.
    • A4LD Upgrade (A4LD to Ford C6): Some owners upgrade the A4LD transmission to a Ford C6 which is a sturdy alternative.
    • A4LD Upgrade (A4LD to Ford AOD): Some owners upgrade the A4LD transmission to a Ford AOD which is a sturdy alternative.
    • A4LD Upgrade (A4LD to Ford E4OD): Some owners upgrade the A4LD transmission to a Ford E4OD which is a sturdy alternative.
    • All Transmission Fluid: Regular transmission fluid changes are critical to prolonging the life of any automatic transmission in the Aerostar.
  • Electrical Issues:
    • Wiring Harness Problems: Due to age, the wiring harnesses can become brittle and prone to cracking, leading to electrical shorts and malfunctions. Careful inspection is recommended.
    • Sensor Failures: Sensors such as the Mass Air Flow (MAF) sensor and oxygen sensors can fail, causing poor engine performance and reduced fuel economy.
  • Suspension & Brakes:
    • Worn Suspension Components: Expect to replace ball joints, tie rod ends, and shocks/struts, especially on higher-mileage vehicles.
    • Rust: Rust is a major concern, particularly in areas with road salt. Pay close attention to the undercarriage, rocker panels, and wheel wells.
    • ABS Malfunctions: The ABS system, if equipped, can develop issues with age, requiring diagnosis and repair.
  • All-Wheel Drive (AWD) Issues:
    • Transfer Case: If equipped with AWD, the transfer case can experience wear and tear, leading to noise or failure. Regular fluid changes are essential.
    • Front Differential: AWD models also require regular maintenance of the front differential.

Driving Experience

The Aerostar offers a driving experience that is typical of a body-on-frame van from its era. It's more truck-like than modern minivans, with a solid feel but also a less refined ride.

  • Pros:
    • Good Cargo Capacity: The Aerostar excels at hauling cargo, especially with the rear seats removed.
    • Towing Capability: Properly equipped Aerostars can tow a decent-sized trailer.
    • Ruggedness: The body-on-frame construction gives it a solid feel and makes it suitable for light off-road use (especially the AWD models).
    • Simple Mechanics: Relatively easy to work on for DIY mechanics.
  • Cons:
    • Ride Quality: The ride can be bumpy and less comfortable than modern minivans.
    • Fuel Economy: Fuel economy is poor compared to newer vehicles, especially with the V6 engines.
    • Handling: Handling is not particularly sharp, and the vehicle can feel top-heavy in corners.
    • Safety: Lacks modern safety features like airbags and stability control.

Buying Advice

If you're considering buying a Ford Aerostar, here's some advice to help you make an informed decision:

  • Years to Look For: 1989-1992 models with the 4.0L V6 and AWD (if desired) are generally considered the most desirable, offering a good balance of power and features. Look for well-maintained examples with documented service history.
  • Years to Avoid: Earlier models with the 2.3L engine may feel underpowered. Vehicles with excessive rust or signs of neglect should be avoided.
  • Pre-Purchase Inspection: A thorough pre-purchase inspection by a qualified mechanic is essential. Pay close attention to the engine, transmission, suspension, and brakes. Check for rust, oil leaks, and any signs of previous accidents.
  • Check for Maintenance Records: Look for vehicles with detailed maintenance records, including oil changes, transmission services, and cooling system flushes.
  • Test Drive Thoroughly: Test drive the vehicle on various road surfaces and at different speeds. Listen for any unusual noises or vibrations. Pay attention to how the transmission shifts and how the brakes feel.
  • Negotiate Price Accordingly: Be prepared to negotiate the price based on the vehicle's condition and any necessary repairs. Factor in the cost of any potential repairs before making an offer.
  • Parts Availability: While some parts are becoming scarce, many are still available through online retailers and auto parts stores. Research parts availability before committing to a purchase.
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