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i HAVE A 1991 FORD AEROSTAR XLT WITH 99000 MILES. THE TRANSMISSION SHIFTS SMOOTHLY AND i HAVEN'T SMELLED ANYTHING BURNING (OIL, TRANNY FLUID) AT ALL. i RELIGIOUSLY DO OIL CHANGES EVERY 3K MILES AND JUST HAD A TRANSMISSION SERVICE COMPLETED. WHEN i HIT THE GAS AT A LIGHT OR LET OFF THE GAS AFTER A HIGHER RATE OF SPEED, HEAR A CLUNK THAT IS IN THE MIDDLE IF THE VAN, i TOOK IT TO A CHAIN TRANSMISSION SHOP, THEY SAID THE TRANNY WAS SHOT AND i NEEDED TO PAY $1900 TO FIX THE PROBLEM. IS THERE A SUPPORT FOR THE TRANNY THAT WOULD BE CAUSING THE NOISE?
THIS VAN RUNS VERY QUIETLY AND IS IN FAIRLY GOOD CONDITION
Here's my general answer (others with more Aerostar-specifics should jump in here too)
The immediate thing that comes to mind is to check the u-joints. When they wear out, you can get a very noticeable thunk or thud when you let off the gas, or coast and then hit the gas again. Sometimes, if you have the van stopped and slip the tranny into neutral and then back into gear, the u-joints will 'clunk' then also.
I would not believe the chain based on what you've said (regular servicing, quiet running, no tranny slipping, etc.).
I'd find a reputable, non-chain location and ask them to check it out and give you an opinion, before spending the money at the chain.
The u-joints are connected to the driveshafts, there isn't a u-joint for the transmission per se. If the u-joints start to wear out (and they do wear out over time/mileage), they can create 'clunks' in the driveline when you accelerate/deccelerate. I am not aware of any automatic tranny condition/problem that has no other symptoms other than the noise you described, that'w why I'm saying that you should check the u-joints first.
Here is a link to an old topic that describes how to check the u-joints for play:
My similar clunk turned out to be worn rubber bushings on that 3 pointed dog leg support that goes from the back axle to the left frame, in front of the axle.
Alas, the dogleg is only sold complete with bushings, from Ford. It was about $300 installed, as I recall. It is a shame for us non stockholders, that Ford or someone doesn't make replacement bushings for Aerostars.
The universal joints range from $7.99 to $25.99 at partsamerica.com I've also found the bushings for the rear upper and lower control arms ( that dog leg thing) for about $22.00 each.
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