that would explain why the body drainage is so poorly designed. just slap it together and hope it holds. fortunate for us, the powertrain is more sound than the body. i have yet to run into major issues with my powertrain (knock on wood). that's what i love about the aero... it takes a licking and keeps on ticking. just the dang body i tell ya... what a shame...

 

It's not just the Aerostar, look at almost any contemporary auto. They all exhibit signs of body rot at one point or another. I've seen just as many *cough* Caravans and Voyagers from the same era with rust issues as well.

The powertrain is definitely the strong suit for these vehicles.

 

Bought my 90 new here in Texas.....has only been in snow one time in Colorado. The body does not have any rust problem. Ditto on my 91.......

I'm sure if I had bought the car in the northeast and used it there I would be having rust problems, but not just with the Aero, but any car......

 

my rocker panels rotted out early it the van's life. the driver side rocker panel to upper body panel joint also has early rust problems. the van was bought new and have been babied ever since.

 

Ford never sold Aerostars in Europe. They started with the Windstar to compete with the Caravan which is very popular here. Every Aerostar here is a "grey market vehicle". The old Aerostars had their headlights simply swapped. On the newer ones, unique solutions had to be found. The parking lights had to be changed from orange to white.

I bought my Aerostar in 1997 in Massachusetts and shipped it to Europe. I agree that the parts could be brought into Switzerland without great hassle. But the shipping costs (enormous) do not justify the result. I am happy with the way I have it. I'll make pics of my "solution" today and post them.

 

that would explain why. after giving this further thought... even if ford is cheap. to get a car/van legally in europe... the headlamps MUST be E code approved. no exceptions. but this does not include cars/vans imported i guess.

 

Well, it depends. When I had my 1992 Buick Park Avenue (grey import), I didn't have to change the lights. The plastic composite lights were proved to be sufficient. I never had any problems with them.
For the Aerostar, the plastic composites were not acceptable, they had to be replaced.
The official importers GM, Ford and Chrysler have to get all their lights approved. Not only the headlights but all exterior lights, up to the license plate illumination. The tail lights have to get approved reflectors (mine are bought extra and glued to the rear bumper), signal lamps have to be orange. Sidemarkers are not allowed and from 1991 on, a rear fog lamp is mandatory. Headlights have to be electronically height adjustable.
Single imports are not treated that badly. Taillights are usually accepted as they are, you only have to add the reflectors.

I now have the pictures of my lights, how can I insert them?

 

tomucen click on your "User CP" at the top of the page and then "edit gallery". Follow the instructions there to set up your gallery and then post links to the pictures by clicking on "go advanced" instead of "post quick reply". In the "go advanced" reply window you'll see the button to add a link to the pictures.

 

Wow, I need to upgrade my lights!

 

Dave, thanks for the guidance.

here's a pic of the front:



and here's aclose up:



Not very nice looking, eh? But it serves its purpose. To change to the pre-facelift parts would make it look nicer, but then I'd have a problem with my parking lights. They have to be white so I drilled holes from behind into the signal lights and stuck in small 5W lightbulbs. Since the glass is also white, it works. If I had the orange glass, I'd have a problem. I think the white glass came with the facelift.

Aero94XP, I just noticed that you're in Vicenza. Are you military or civilian? If civilian, what conversions did you do for Italy?

 

Need to git meself sum.

 

Tomucen,

Way to go!

Did you make that bracket that goes around the light housing, or was that an original part?

Also, I think there are versions of the H4 light housings that have the "city light" option; a small light bulb above the primary bulb for the parking light. But what you did is just fine, I'm sure.

 

no, that bracket is custom made by a shop, cut from a sheet of stainless steel.

The lamps with the hole for the parking light bulb was not available at the time I needed it so I decided for the other way with the bulb in the signal lamp. It has the advantage that the sidemarker is also lit by it.

 

Take the old one and split the lens off the front half. They come with plastic rivets holding it on the housing. Then you can clean it real good. Then use a normal rivet gun to put it back on.

Don't pry on it, Just drill it out and use a small screw driver to seperate it.