I want to add a Ford 4x4 Van to my collection. I was thinking of starting with an older, E-series van or even a 93 to 97 Aerostar. A friend of mine had made good use of an Aerostar as a hauler and a camper. The Aerostar is very maneuverable in tight spots.

Being used to an 1986 F-250 supercab I could also get by with the larger less maneuverable E-Series platform. I'm thinking of the model years from approximately 80 to 96. I'd like to know how the frames for the E-series vans compare to the Pick up F-series frames. Are they similar in the same size, years, ie 150-250-350...etc? I was thinking they might be the same or very similar to the pickups. Varying in tonnage and length.

Would be interested in hearing which years of the E series or Aerostars people think were the best. Also Engines for the vans, I think the Aerostar came with a few choices of 4 cyl and 6 cyl choices. Which engines are the best in vans. I have a 6.9l IDI in my pick up and would not be adverse to having that same engine in a E-series van.

Which ever van I get I hope to make it a comfy camper while still allowing for some hauling. Maybe build in some removable furniture for quick conversion from camper to hauler. Perhaps put a rack on top.

Thanks for any advice as I am currently shopping for a van.

Big Blue 2

 

Check government surplus as they sometimes have them for sale. Easier to get one already built. There are a few articles on here about builds. Definitely need fabricator skills. The frames are different (van a tad wider I believe) and I think the 350 is a heavier frame. Also heavier duty rear axle if you need to haul the weight. If your wanting just a little more clearance and traction I'd try for a lift (not much available) and a posi unit in the rear. As far as years I'd go for the newest your budget allows that is fairly rust free and of course lowest mileage. I'm not familiar with the newer mod motors in the vans but I have a 5.4 in an expedition that does well with 280k on it. My van has the 460 dino drinking beast. Its a dog for its size but I enjoy it. I know nothing on the Aerostars. Do some reading on these forums with searches and you should find a ton of information on both vehicles.

 

Good luck. I'll be watching this thread for your project. I thought about getting a 4x4 kit from Expovans for my 06 E350 or from Boulder 4x4 for my 91 Chevy G20. Decided both would be too much money and work beyond my skills and tools. Now I've settled on getting an AWD Astro Van and putting in a transfer case from a blazer with 2HI, 4HI, 4LO since that's simpler and less expensive. I hope to find a conversion van trim so i can get the captain's chair and bed/bench layout. There's a company called Journey Offroad which has a kit to do a solid axle swap on the astro along with a how to on their website with pictures and info.

 

My personal opinion on your general question is rather than go through the process of collecting, assembling/building such a vehicle I'd first see if something doesn't already exist---in this case the E-Series can be had with complete fully operational 4x4 from one company called Quigley. Within the smaller camper/RV van world that is one of the best available---they use all Ford components (some from F-Series) to create a very well engineered final product.

The huge advantage there's not a lot of special engineered parts which can be hit or miss quality-wise in a lot of instances. Think of the glut of conversion vans from the 80's and 90's where the original builder has been long out of business, some of the parts used available only through them even when they were still in business.

Camper/RV conversions are fully discussed on a site called Sportsmobileforum.com---it might be worth your time to first look around there. A few of us in this FTE sub-forum are already there, the two sites being somewhat compatible in a lot of ways.

HTH

 

Check the VAN forum at Expedition Portal.
As to the smaller van, I'd look for an Astro/Safari. They had them in AWD. Also, if you had a standard 2wd version, a front clip from a Blazer will fit underneath it I believe. You can then run a V6 or V8.

 

I found this web page few years ago when I though about making my 95 E350 bus 4x4.
How to make a 4x4 Ford Van Construction Details Page

 

Thanks everyone for your input. I should clarify that I am looking to get a van that already has 4x4 or AWD capability. When I said conversion I was not thinking of converting from 2WD to 4WD, though it is a possibility. I was referring to converting the use of the van from passenger or cargo to a camper. Envisioning a bed, closet, kitchenette. Wanting to keep it simple and cheap and easily convertible to a hauler, or perhaps install a sturdy rack on top.

I see that we do have an Aerostar forum here on FTE so will post over there too for which engines, transmissions and rearends were available and which are loved and maybe not so loved. I wouldn't be opposed to going to other makes such as the Astro or Safari as suggested. I am a Ford guy I guess so was thinking of staying with Ford. If I go with an E series van there will be a lot of similarities with my F-250 in terms of DIY maintenance and possible cross use of parts.

I have a 6.9l with a T-19 4 speed in my truck and it has been virtually bomb proof with over 400,000 miles on it. Also the 10.25 rear end with the tall 3.55 ratio...highway rig...but off road with the low range 4x4 can still pull a house off it's foundation. So would like to stay with a manual transmission on a E-series platform too. 6.9l would be a fine choice of engine as well.

For the Aerostar option would hope to find one with a 5 speed manual and a 4.0l v6. Definitely want the extended van and AWD.

 

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