The door opens just fine, the latch appears to work good when you lift the latch end of the door. When open the door hangs about 1" lower -- the pinstriping doesn't line up. If you don't lift it up, the latch just bangs the stop...
I think the mounting bracket holding up the sliding track has broken (on the inside of the catch/stop), and the track flexes downward as the latch mechanism approaches that ****. Can that track be replaced with home tools? Can the catch/stop **** be replaced (is it a threaded fitting?) or is there more adjustments or fixes that can be done without removing the door?
I believe there is also a sliding pad that is worn, but the local dealer wants $187 for that part alone.
Schools coming soon, and I need to get it fixed.... I'm not sure where to start first - Any advice would be greatly appreciated. - Thanks!

 

As far as the sliding track is concerned, you can open the door all the way and look at where it is mounted to the body. Basically, there are three or four bolts (they are flat headed and flush with the track) that hold the track to the body, including one that is on the inward side of the track atr the very end right next to the opening.

I just picked up a 96 Aerostar and the track itself was broken right next to thatt inner bolt. I did not want to take the interior panel apart (partial or complete - it looks like a fair amount of busy work to get to the inside of the body panel to remove all the bolts that hold the track in place). Instead, I removed the top roller assembly (two nuts on the top come off and then the top edge of the door will start to fall away from the van - have an assistant hold the door so it doesn't swing open too far) then I drilled a small hole through the track and the body itself. I then used a self-tapping sheet metal screw (small) to help hold the track in place. My theory is that it will be a temporary fix for now, and that the only time that sheet metal screw is holding any weight is right when the door is opened. (when the door is closed, the post is holding the weight) . I was careful to use a small screw, and put it as close to the end of the track as possible so that it didn't interfere with the sliding parts.

I just told my wife and kids not to make sure that they slide the door open every time, and not leave it 1 - 3 inches open with the weight on that screw.

Another fix I am considering is having a friend use his MIG welder to fix the break in the track. I am not sure what effects the welder would have on the paint near the track, so I haev held off on that attempt for now.

In any case, that temporary fix has worked quite well for the last two months. The door closes very smoothly now.

Hope this helps - I am not sure what to say about the slider pad, I don't think my stealer charged anywhere near that amount when I needed to fix up my old Aerostar...

 

Had a similar problem with my '92...Turned out to be a plastic roller on the bottom track. You can't really see it unless you lay down with the door open... cost about $30.00 from the dealer for the part and had to drill out the rivets that held the lower cover plate in so I could remove the assembly... BE SURE TO SUPPORT THE DOOR WHEN YOU DO THIS...It's not too hard to remove the old roller, but does take some patience, a vice and a big hammer.. On reinstall, be sure when you re-rivet the cover plate leave clearence for the track and roller to pass...works fine now... Hope this helps

Ron

 

I agree with rlmdad on the lower roller assembly. I had to replace the roller on my old 91. I didn't have to drill out any rivits. However, if your door is drooping 1", I don't think it's the roller itself.

Look at the bracket at the lower inside latch side of the door. There are three bolts that hold this in place. Make sure that the bolts have not come loose.

Also look at the roller and make sure it is there and has not come off. That might cause a 1" droop. Check the path the roller uses.

On mine, when the door would droop (due to worn roller) the upper roller tended to come out of it's track. I had to come and rescue my wife when the door poped out of place a couple of times.

There are three rollers on the door. The one away from the latch supports the left/back of the door. The one at the top keep the door in alignment (in/out) while the lower roller supports the weight (latch end of door) and alighment up/down.

The problem has to be with the lower roller assembly in some way. Take a closer look and let us know what you see.

 

Recently, the sliding door on my '93 Aerostar balked angrily when I tried to close it. Looking down in the track, there was a 'blob' of black rubber/plastic material, reminiscent of a wad of black electrical tape. Could this be the remnants of the plastic roller referred to by rlmdad?

I talked to the service group at the dealership in Kirkland, but they were clueless and wanted to charge $$$ to 'evaluate'.

In the meantime, the door sounds like it is scraping on open and close. Where does one find such a roller replacement?

 

I got mine from the dealer. It's not cheap but I have no idea where to get another except from the junkyard. They are hard to find there.

 

Isramos

That's exactly how it sounds if the roller has failed because the lower track mechanism is scraping along the bottom. The roller can be obtained from the dealer and it's not cheap. I think mine cost about $30.00 just for the roller and I had to disassemble the old roller and press on the new roller. If you have time you might try looking for a replacement roller, but if you're like me you need to fix the sliding door asap. I would avoid getting this roller from the junkyard as it would in all likelihood be in as bad a shape as your original.

 

True, True.

I had to order mine from the dealer. "IF" you a good one at the junk yard you can change the whole assembly. Change just the roller is a real PAIN.

 

I have a 93 aerostar and recently the sliding door stopped opening. I cannot even make it budge. I have taken off the panel and looked at the inner workings. However, I cannot seem to get to the rear of the door to see if the door is off track or if something is jammed in there. Does anyone know what to do in this case.

 

Had a similar problem with my '92...Turned out to be a plastic roller on the bottom track. You can't really see it unless you lay down with the door open... cost about $30.00 from the dealer for the part and had to drill out the rivets that held the lower cover plate in so I could remove the assembly... BE SURE TO SUPPORT THE DOOR WHEN YOU DO THIS...It's not too hard to remove the old roller, but does take some patience, a vice and a big hammer.. On reinstall, be sure when you re-rivet the cover plate leave clearence for the track and roller to pass...works fine now... Hope this helps

Thanks rlmdad now I know what's wrong with my '91 I really like her and want to keep her up.

 

68torino,

Glad the info helped. I like our '92 extended a lot also. It's great for traveling with the four of us. With two boys it's great that everyone has their own area.

Now I need to change a leaking rack and pinion, but that shouldn't be much trouble.

Ron

mbut,

The latch for the sliding door is at the rear of the door. Sometimes the linking rod from the handle to the rear mechanism gets bent out of shape making it hard to unlatch the door. Since you already have the interior trim off the door try to release the latch manually. Also, check to be sure the door lock is not engaged.

Ron

 

Finally decided to just buy a replacement roller from the dealer. Part number E69Z-1125001-A, called a RLR ASY, for $33.71.

Removal of the bottom door bracket on my 93 Aerostar was simple, requiring removal of 3 bolts, then finagle the roller assembly to expose the single bolt that holds the roller on the assembly. The roller piece can then be twisted out of the track.

As described by rlmdad, though, removing the roller itself required a very sturdy vise and a large hammer! Once removed, though, everything was easily reassembled, and I can now have passengers again.

Thanks all for your tips.
Scott