Hey all, it's been a while since stopping by the one and only Aerostar forum. Feels good to be back! I sold my Aerostar just over a year ago and have been keeping my eye on the for sale market ever since. To make a long story short I finally found one that seriously caught my interest. A ‘90 AWD extended version with 105k miles!

Everything appears to be well above average but one thing concerns me. My last Aerostar was RWD and I have very little knowledge of the AWD systems used on these vans. I’m mainly concerned with major parts failing; transfer case, front diff, transmission (due to extra stress with the AWD), and anything else specifically related to the AWD system. ’90 was the first year for AWD and there was an ‘update’ for some of the AWD components in (I believe) 1992. That in itself concerns me a little.

I fully realize older vehicles need extra love but don’t want an instant money pit. This van would be used for ‘work’ related stuff and camping but cared for by an OCD owner. I would not be towing anything too heavy or hauling huge weight. If this is ‘the one’ I plan on keeping it very long term.

Any input on this is much appreciated!


- justin

 

I have one exactly like that; a 1990 AWD. I got mine in 1994 with 24k miles, and I've put over 120k miles on it, with no major problems from the AWD sysem. The worst problem it had was all the oil leaks in the engine, but that was true for the 2wd models as well. The oil pan gasket the worst to replace; I had to drop the entire drive train, front and back, and it was still hard to drop the pan. Here the job was a bigger chore than on the 2wd model because of the transfer case and front axle.

I once thought I had a problem with my transfer case, but after going through the troubles of replacing it, I found the problem elsewhere. The change in 1992 was to eliminate the speed sensor in the case, when Ford started to use the rear axle sensor to get vehicle speed.

But obviously, if you put it through heavy use, you can wear out parts faster. I heard folks on this list having to replace the front half-shafts. The rubber bellows that go around the CV joints on the half-shafts and the front drive shaft can crack, and need to be replaced before those joints get exposed to dirt and moisture, so you should check those regularly.

I forgot to rotate my tires one year, so the fronts and rears wore differently enough that their speed differential caused the AWD mechanism to lock the center differential when I was going slowly around a parking lot, causing binding, and really loud bangs when the gears skipped the Morse chain. As an emergency fix, I removed the AWD computer under the driver's seat. So it's important to make sure the tires are at the same size.

Some folks here claim that the ATF used in the front axle is insufficient to protect it, so they recommend replacing it with gear oil. I tried that, and the result was the gear oil has so much more viscosity that it heats up more, to the point that even when you put the right amount of oil in the case, it will expand enough from the added heat to puke out the vent tube. If you're driving at any speed, the oil blows onto the catalytic converter, where it burns and makes a lot of smoke. I am checking its level regularly, and slowly replacing the boiled off oil with ATF.

 

just my opinion but at this point in the age of a AWD Aerostar, you're only buying someone else's problem, stick to the RWD Aerostar, you'll be happier.

 

This!!!

forget buying parts for the driveline special order if they can even be found

 

Actually I am going to disagree with Jose, yes there are more parts, but they are all available After market and very reasonable.

Most common failure items are CV shafts, U-joints, Ball Joints, and Hub assembly. If you get a 2wd with a fubared bearing, good luck finding a replacement spindle, you can replace the whole assembly on the AWD.

You don't see Transfercase issues or Dif issues.

I personally recomend the AWD if you are going to be doing any type of bad weather driving.

 

I also suggest that if you get a 2wd, make sure you get one with a limited slip rear end. An open rear end becomes almost useless in the rain or snow. My 4wd version came with a limited slip rear, so in the worst case, it gives my 3wd, since the front is open. But I've heard that some 4wd models come with open rears as well, which I find puzzlingly, as it's far less effective.

 

The '91 E-4WD is the same throughout and I have had very little problem with the major components you were worried about. The transmission was upgraded with better components to go with the 4 wheel drive versions.

Just to give something to worry about, do you realize those older odometers only have 6 digit capacity? Mine says 8,500 miles but it has turned over 3 times now. But look on the bright side. We are perhaps the only vehicles left with speedometers indicating an 85 mph top limit!

 

It's my opinion that you buy an older vehicle like this only if you have another vehicle that you could drive if this one would break down. See, with the Aero, the parts are still out there, but you just have to be patient on getting them. I know of a web site that is still advertising transfer cases for the '92-'97 Ford Aerostar. These transfer cases are brand new (not refurbs), and are $495. Heck, I'm almost tempted to buy one just in case I'd ever get an AWD Aerostar. (Well, almost)
I'm posting this as I'm parting out my '93 and I'm looking to find another in good shape.

 

I would like to thank everybody for chiming in on this thread. Your input is VERY much appreciated! I plan on living in CO long term and decided an AWD Aerostar is for me. For those curious, the van I mentioned in the first post was not meant to be and sold to somebody else. The search continues......

 

I have 3 of em..I would only buy a 96 or 97 now...AWD are the only way to go IMO if it snows where you are. 96,97's have electronic trannies. I like em..97 has engine improvements. I had a 94 awd also. The heads fell apart. Cracked etc.

 

I had a '90 awd xlt that was still running well at 220K when I got rid of it. No major failures along the way, some annoyances, but with cargo coils at the back to level it I discovered it could driven with some pace. When solo of course.
Now I've taken on a 93 rwd shortie with the M5OD, looking for mid-20s on trips to see relatives and friends a few hundred miles away. We'll see how it works out