96 Axle replacement
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Junior User
Joined: Apr 2001
Posts: 96
Likes: 0
96 Axle replacement
Okay, so after many years of a rear end noise that is getting worse, (God bless my Areo), I need to replace my rear axle. It's a B4 and I was wondering if there would be any advantage of going to an 8.8" vs the 7.5" that's in it. Would it be a direct bolt up? I don't tow like I used to,(#6500 travel trailer),....obviously what lead to the failure, but this van just works for me and I still will occasionally need to tow a few tractors around. Thank you!
Lead Driver
Joined: Sep 2003
Posts: 7,013
Likes: 205
From: SoCal
The 8.8" axle is going to be stronger than the 7.5", so it would be a good swap just for that purpose. I think it was only available on 2wd vans with the 4.0L engine. But it should swap into all Aerostars. If you're looking for one, try to find one with Traction-Lok.
Freshman User
Joined: Feb 2016
Posts: 35
Likes: 0
From: Las Vegas nv
I was thinking of this also I contacted some members on the other fourm and it appears the awd had the 7" rear. The rwd had the 8. This is a common swap my awd has a mustang aluminum drive shaft. I don't know why some have aluminum and some steel. I would look for a possi rear if your rwd.
Lead Driver
Joined: Sep 2003
Posts: 7,013
Likes: 205
From: SoCal
My AWD uses a steel driveshaft, as did all the other AWD models I saw in the scrapyard. No problems with vibrations or cracking the TC.
My 2WD van used an aluminum driveshaft. It was a little longer due to no TC.
My 2WD van used an aluminum driveshaft. It was a little longer due to no TC.
Posting Guru
Joined: Jul 2004
Posts: 2,416
Likes: 1
From: Mitchell, SD
Hhhmm,I know there is a TSB about using Aluminum driveshafts on the AWD's, and they are used a lot on the Mustangs as a cheap driveshaft swap due to being aluminum.
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Junior User
Joined: Jan 2008
Posts: 59
Likes: 0
From: USA - New Mexico
I think all (or most) of the AWD Aerostars originally had steel driveshafts but they where recalled and replaced with aluminum ones https://www.automd.com/recall/campaign_c16277/
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