Okay, so after many years of a rear end noise that is getting worse, (God bless my Areo), I need to replace my rear axle. It's a B4 and I was wondering if there would be any advantage of going to an 8.8" vs the 7.5" that's in it. Would it be a direct bolt up? I don't tow like I used to,(#6500 travel trailer),....obviously what lead to the failure, but this van just works for me and I still will occasionally need to tow a few tractors around. Thank you!

 

The 8.8" axle is going to be stronger than the 7.5", so it would be a good swap just for that purpose. I think it was only available on 2wd vans with the 4.0L engine. But it should swap into all Aerostars. If you're looking for one, try to find one with Traction-Lok.

 

you might need a shorter drive shaft or a different u joint.

 

I was thinking of this also I contacted some members on the other fourm and it appears the awd had the 7" rear. The rwd had the 8. This is a common swap my awd has a mustang aluminum drive shaft. I don't know why some have aluminum and some steel. I would look for a possi rear if your rwd.

 

All AWD "Should" have the aluminum drive shaft, the original steel ones caused issues with vibrations and cracking transfer cases.

 

My AWD uses a steel driveshaft, as did all the other AWD models I saw in the scrapyard. No problems with vibrations or cracking the TC.

My 2WD van used an aluminum driveshaft. It was a little longer due to no TC.

 

Hhhmm,I know there is a TSB about using Aluminum driveshafts on the AWD's, and they are used a lot on the Mustangs as a cheap driveshaft swap due to being aluminum.

 

I think all (or most) of the AWD Aerostars originally had steel driveshafts but they where recalled and replaced with aluminum ones https://www.automd.com/recall/campaign_c16277/

 

I wish I had seen this note 20 years ago. I had my van checked at my local dealership, and they always told me there were no recalls for it. Too bad, as that dealership is no longer there.