I have a '92 Aerostar XLT with a rear control arm problem. The bushings have worn out and the rear end floats side to side as much as 1 1/2 inches. Ford says one bushing comes in the arm ( no longer avail ), one is a press in (no longer available), and the other is like a strut bushing and is available but without the other 2 there is no point in replacing the one.
Does anyone have any suggestions or answers on how to fix this enormous problem???

 

You might try to measure the sizes of those bushings and see if a company like Energy Suspension makes anything close that you can use as replacements. Failing that, see if there are Aerostars in your local junk yard that have arms in better condition.

 

I had the same problem with my '94 last fall. Mine ended up being the pressed in bushing above the gearbox. broke it loose with a 6 ft pipe cause 250 ft/lb torque. Bolt was so rusted it was 1/2 the diameter in the middle than at the ends. (thank you northern winters) metal insert in the center of the bushing was very oblong because the bolt clearance was so large. $100 at ford dealer, if i remember right there were only a handful left across the country at that time. guess the mfg discontinued product line. Tried to get this at the local auto parts store before going to the ford dealer and they sold me 1 but it was so not the right bushing.(they swore up and down it was) I looked in the local part yards but up here they all look the same. maybe have better luck finding a good one in the south. If you do end up attacking this, be warned of the EXTREME press fit. I had to torch the old one out, polished up the bore real nice. heated up the bore and then used a lot of swear words. if i ever had to do it again probably would remove the axle and take somewhere where they have a hydraulic press. A lot more work but worth it in the end.

 

i have that problem now and i heard nobody sells them anymore so i have to go to a u pull it. the arm isnt bad but the bushings are. actually the bolt egged out the hole on the one side of the frame and i have to weld some kind of small plate to make a new hole. so since the bushings are pressed on is there a way to replace them or do i need to get another arm? also how hard is it to take out the arm and replace it with another?

 

1990/97 Aerostar:

F39Z-5500-A (replaced FO9Z-5500-A) .. Rear Control Arm-UPPER-Includes one bushing (not available separately). There are two other bushings that do not come w/the arm / Obsolete

No Ford Dealer or obsolete parts vendor has any.
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FO9Z-5K679-A .. Thrust Bushing-located on axle housing-opposite FO9Z-5K789-B / Obsolete

No Ford Dealer or obsolete parts vendor has any.
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FO9Z-5K789-B .. Upper Bushing-located opposite FO9Z-5K679-A / Obsolete

FOUR available NOS (1 each: AK, KY,TX, <acronym title="Page Ranking">PR</acronym>). No other Ford Dealer or obsolete parts vendor has any.
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1986/97 Aerostar:

E69Z-5538-A .. Rear Control Arm-LOWER ~ Includes bushings (not available separately) / Obsolete

ONE available NOS

 

Just curios, it has been a while sense I have looked at my rear end.

But do these look correct?

Moog - Control Arm Bushing Kit rear lower
Part Number: K8812

Moog K8812 - Control Arm Bushing Kit | O'Reilly Auto Parts

Moog - Control Arm Bushing rear upper
Part Number: K8733

Moog K8733 - Control Arm Bushing Kit | O'Reilly Auto Parts

 

PN K8733 looks like the thrust bushing for the rear upper control arm. I don't suppose they have a pair for the front pivots of the upper arm?

 

it's what MOOG-Fed Mogul show for our Aeros

Federal-Mogul Resource Center - Vehicle Look-up

here's a better price on them also.
haven't checked RockAuto

MOOG-K8812 Rear Lower Control Arm Bushing Kit Made By MOOG

 

So looks like the bushings are available, but the trick is to remove the old ones and install the new without destroying the control arms in the process.

 

auto/truck alignment/suspension shop or auto machine shop will have all the bushing press tools needed.
or auto restore shop that works on old suspensions restores.
$25 and no headaches later.

 

reading over these old post regarding rear suspension problems on the aerostars. today I purchased upper and both lower arms from salvage on aero that had 170,000 less miles than mine and the only bushing I did not get is the one I needed the worst. after some serious inquiry ford gave me # 5F9Z-5K789-AA and it swaps with several other later vehicles even though it shows obsolete for aerostar. that # is the bushing on the rear end that the arm attaches to, so they say and they are available, scarcely. The Moog #K8812 is correct for the lower arm bushings.