I'd like to know the best method of removing a 4.0l from a 95 Aerostar AWD. It needs head gaskets, Oil pump, water pump ect basically a rebuild. Now I am a mechanic but too many people are telling me different stories on this rig. Some say from the front, others drop the engine cradle completely. wich is easier,? well let's say smoohter and or quicker?
I need to flip this rig in two days tops! even if it means new heads so I don't have to wait for the machining. I personally don't see a way to even torque the heads successfully if I could do an inframe. If an inframe was possible it should definately be a poster illustration for back injuries!
here's JT-hill's thread w the link to his how-to on pulling the engine out the front. looks to be the easyest way. i read in hayes how to drop the engine... it's complicated. you'd need a lift, and have to undo most of the front suspension in order to lift the body off of the engine/front suspension. too much to do.
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93 3.0l xlt extended aerostar
mods:
800 watt sound system.
200+ farad kenetic battery + 875 cca reg. battery
2" catback exhaust w new flexpipe and cherry bomb muffler.
4g alt. wiring
Gutted stock airbox
2nd row bucket seats
here's JT-hill's thread w the link to his how-to on pulling the engine out the front. looks to be the easyest way. i read in hayes how to drop the engine... it's complicated. you'd need a lift, and have to undo most of the front suspension in order to lift the body off of the engine/front suspension. too much to do.
I do have access to lifts,.. I work at Midas lol. JT is removing a 3.0 liter in those pics but yes I do see that it may come out as ,... ummm I can't say easily! it will come out that way I suppose. It just doesn't seem like anyone has done the 4.0 liter and an AWD either I hate to toss this van it is excellent on fuel and handles Alaska weather great but WOW! what a nightmare.
Last edited by thunderbird885cc : 04-01-2008 at 02:32 AM.
Reason: left out the AWD part, very important tid bit
4L heads are usually done inside the engine comp. but it does take 2 people to put them back in. lots of blind wrenching.
if you pull the engine
lift not needed, just engine crane and tranny jack.
lots of work. have to drop back the TC then the transmission
remove upper intake manifold aka plenum for clearance.
have your replacement heads already prepped by machine shop. you will probably find problems with the old ones that negate just a quick flop, recedded exhaust valves, combustion chamber cracks, etc. common of 4L heads.
probably the best to pull engine if you are not positive that there are no other problems such as rod bearings, cam. pan is a pain to drop on the AWD 4L in frame.
no problemo on 2 days with good prep of heads and all parts gaskets on hand and a good selection of sockets and extensions plus air tools for speed. the plenum bolts take 10mm female Torx socket. the head bolts are Torx also, male socket.
use a Chilton's or Ford Serv. cd for instruction details
get the 2 piece Fel Pro lower intake manifold gasket
probably 75% of the 4Ls still on the road have had the head gaskets done at least once
Well that settles it for me 80% front 20% drop the whole works thanks guys for all the info 3.0 vs 4.0 yeah not a big difference it's the AWD that was my biggest concern
it needs too much to just do the heads so it's comin out. I think I'll photo this one and post a link somewhere for anyone interested in the 4.0 AWD engine removal. Think what I'll do is anticipate the worse and order new heads before the tear down. If the heads prove to be ok i read somewhere that there a 3 million still on the road chances are someone could use a set.
please do! i have 93 awd w almost 200k and atleast 7 old owners, and oil changes were every 15k.... i know what i'm going to be doin in the next year or two.
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93 3.0l xlt extended aerostar
mods:
800 watt sound system.
200+ farad kenetic battery + 875 cca reg. battery
2" catback exhaust w new flexpipe and cherry bomb muffler.
4g alt. wiring
Gutted stock airbox
2nd row bucket seats
4.0 liter removal
and or quicker?
lol. JT is removing a 3.0 liter in those pics but yes I do see that it may come out as ,... ummm I can't say easily! it will come out that way I suppose. It just doesn't seem like anyone has done the 4.0 liter and an AWD either I hate to toss this van it is excellent on fuel and handles Alaska weather great but WOW! what a nightmare. 
Front Pull
