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My Aerostar seems to have to much camber as it is wearing the outside of the front tires. Upon investigation I found that the passenger side upper control arm adjustment, where you put the shims in to adjust camber has no shims installed? Thus I can't remove any to set the wheel correctly.
The brackets that the upper control arm attaches, appear to look like they can be moved(repositioned) on the frame? The rear bracket for sure as you can see the slot in the attachment holes, but the front one I am not sure, I can't see a slot? Has anyone done this before or can shed some light??
Mine had the same frustrating problem, even though repeated alignments indicated everything was in order in terms of camber, caster, etc. I too, was convinced there was just too much positive camber in that front end.
I finally rebuilt the entire front suspension. In retrospect, replacing the sway bar links had the most profound effect on this tire problem. It was immediately apparent the van did not roll as much as before. It took a long time to convince me as almost all my driving is back and forth to work over relatively straight roads. I could not see how I was getting enough roll onto the outside tire edges to cause this kind of severe wear. Since the rebuild both front tires are now wearing evenly. Before, I chewed up a new set of tires after just 22,000 miles, even with rotations at 5,000 mile intervals.
Since the sway bar links are so cheap and easy to replace, try replacing those first. If still not satisfied, you can replace the lower control arm bushings. The lower ball joints were still in good shape even after 200,000 miles. The uppers and tie rod ends had been replaced earlier.
I will most certainly give them a shot. The Van does not pull either direction. I am off on the higway for about 600kms this weekend and will see what happens...
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