Gearbox
Lead Driver
Joined: Sep 2003
Posts: 7,015
Likes: 208
From: SoCal
What kind of gear box?
The 4wd versions of the Aerostar replaced the long tail shaft housing with a shorter housing that mated to a transfer case, so there is some space for some kind of gear box behind the main case of the transmission. You need something that matches the rear bolt pattern of the A4LD transmission.
The 4wd versions of the Aerostar replaced the long tail shaft housing with a shorter housing that mated to a transfer case, so there is some space for some kind of gear box behind the main case of the transmission. You need something that matches the rear bolt pattern of the A4LD transmission.
Thread Starter
|
New User
Joined: Jun 2019
Posts: 21
Likes: 0
manual
This Areostar belong to my father who is passing it on to me. The transmission has been to the shop twice because all tranny fuild was dumped on the road in traffic. It is a 1993 rear wheel drive 3.0L xl. Inspected today and see signs of leaking from the front and rear of the tranny. Just wondering if I could drop a manual gearbox in and forget about the automatic transmission.
Thread Starter
|
New User
Joined: Jun 2019
Posts: 21
Likes: 0
M5R1
Ok thanks, I was reading about that transmission. I will see if I can find a Mazda, ranger or bronco in my neck of the woods. Here in Jamaica a trip to the tranny shop is $90,000 ja ( rate is $132.00 x $1 us.
Tuned
Joined: Aug 2009
Posts: 402
Likes: 16
An interesting exercise for a hobbyist but, having done an auto->manual swap before, on another vehicle, I can advise you that it will be cheaper and more productive for you to fix /maintain /update your current auto tranny.
You would otherwise be faced with sourcing and engineering for...
- Tranny, in known good condition
- Cross member, possibly different
- Shifter, if not integral to the box
- Driveshaft, typically a different length
- Clutch (several components)
- Flywheel ( instead of flex plate)
- Pedal set
- Hydraulic reservoir & lines
- Wiring harness, to mod the operation of backup lights and PNDL lockout.
You would otherwise be faced with sourcing and engineering for...
- Tranny, in known good condition
- Cross member, possibly different
- Shifter, if not integral to the box
- Driveshaft, typically a different length
- Clutch (several components)
- Flywheel ( instead of flex plate)
- Pedal set
- Hydraulic reservoir & lines
- Wiring harness, to mod the operation of backup lights and PNDL lockout.
Thread Starter
|
New User
Joined: Jun 2019
Posts: 21
Likes: 0
An interesting exercise for a hobbyist but, having done an auto->manual swap before, on another vehicle, I can advise you that it will be cheaper and more productive for you to fix /maintain /update your current auto tranny.
You would otherwise be faced with sourcing and engineering for...
- Tranny, in known good condition
- Cross member, possibly different
- Shifter, if not integral to the box
- Driveshaft, typically a different length
- Clutch (several components)
- Flywheel ( instead of flex plate)
- Pedal set
- Hydraulic reservoir & lines
- Wiring harness, to mod the operation of backup lights and PNDL lockout.
You would otherwise be faced with sourcing and engineering for...
- Tranny, in known good condition
- Cross member, possibly different
- Shifter, if not integral to the box
- Driveshaft, typically a different length
- Clutch (several components)
- Flywheel ( instead of flex plate)
- Pedal set
- Hydraulic reservoir & lines
- Wiring harness, to mod the operation of backup lights and PNDL lockout.
I have found a 91 sreostar with a burn fuel pump, could that tranny be used
Trending Topics
Lead Driver
Joined: Sep 2003
Posts: 7,015
Likes: 208
From: SoCal
All those manual parts could probably be adapted to your automatic van, but if the only thing wrong with the 91 is the burnt fuel pump, it would be a lot easier just to replace that, compared to the list the Rojostar provided.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
3 Best / 3 Worst Parts of Modern Ford Ownership
Brett Foote
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches
Pouria Savadkouei
Every 2026 Ford Engine Explained
Brett Foote
10 Ugly Ford Trucks That We Still Kinda Love
Joe Kucinski
10 Things Every Truck Owner NEEDS (2026 Edition)
Michael S. Palmer
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Verdad Gallardo
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
Tuned
Joined: Nov 2011
Posts: 306
Likes: 15
Is it dumping fluid because its overheating? Hows the radiator? Did the seals get replaced in the tranny?
My 3.0 was doing to same thing when run hard with the A/C in the Florida heat.
New radiator and new seals in the tranny fixed it
My 3.0 was doing to same thing when run hard with the A/C in the Florida heat.
New radiator and new seals in the tranny fixed it
Tuned
Joined: Sep 2007
Posts: 455
Likes: 6
The Ford A4LD: Get To Know Its Problems And How To Prevent Them google a4ld front seal fix. its a known problem.
Lead Driver
Joined: Sep 2003
Posts: 7,015
Likes: 208
From: SoCal
I like how the article states that the A4LD is one of the worst transmissions that Ford ever made. I've heard enough stories to believe that. But I've been fortunate to not have had any problems with mine. I have replaced one of the stock coolers with an aftermarket version about 10 years ago. The biggest problem I've had with it was the kick-down cable not wanting to keep its adjustment, which causes the transmission to spin freely sometimes when I tried to kick down.
Tuned
Joined: Aug 2009
Posts: 402
Likes: 16
Meanwhile I've been into Frankentranny twice in the past 10 days,
and now consider myself a well seasoned technician.
Current story #1: OD sprag and obliterated frictions as per Zenish link. Root cause unknown, not proven, but I was goofying around with the gear shifter at the time.
Overall tranny health lasted only 4 trip, 15 miles total, leading to current story #2: reverse gear gone. Was due to rev piston not seated properly on rev band during fix #1.
Rev piston shaft bent, tip sheared, piston seized, rev band not applied, no reverse gear.
During fix #2, a torrington started loosing its needle bearings.
****
My point is not to contribute to the pile of stories but to point out how easy and quick it is to get into the unit and make repairs.
The biggest headache is the dwindling support in the parts channel and is getting worse quickly.
I'm managing my inventory of replacement parts and, for instance, now have two sets of OD sprags on the shelf, two friction kits, etc.
Long term I'm looking to adapt something newer, more robust, better support, 6 speeds.
****
Elsewhere I will (someday) do a couple of write-ups, one on how to very quickly pull and install the unit.
{Done: Transmission, pull / install notes}
and now consider myself a well seasoned technician.
Current story #1: OD sprag and obliterated frictions as per Zenish link. Root cause unknown, not proven, but I was goofying around with the gear shifter at the time.
Overall tranny health lasted only 4 trip, 15 miles total, leading to current story #2: reverse gear gone. Was due to rev piston not seated properly on rev band during fix #1.
Rev piston shaft bent, tip sheared, piston seized, rev band not applied, no reverse gear.
During fix #2, a torrington started loosing its needle bearings.
****
My point is not to contribute to the pile of stories but to point out how easy and quick it is to get into the unit and make repairs.
The biggest headache is the dwindling support in the parts channel and is getting worse quickly.
I'm managing my inventory of replacement parts and, for instance, now have two sets of OD sprags on the shelf, two friction kits, etc.
Long term I'm looking to adapt something newer, more robust, better support, 6 speeds.
****
Elsewhere I will (someday) do a couple of write-ups, one on how to very quickly pull and install the unit.
{Done: Transmission, pull / install notes}
Tuned
Joined: Sep 2007
Posts: 455
Likes: 6
Meanwhile I've been into Frankentranny twice in the past 10 days,
and now consider myself a well seasoned technician.
Current story #1: OD sprag and obliterated frictions as per Zenish link. Root cause unknown, not proven, but I was goofying around with the gear shifter at the time.
Overall tranny health lasted only 4 trip, 15 miles total, leading to current story #2: reverse gear gone. Was due to rev piston not seated properly on rev band during fix #1.
Rev piston shaft bent, tip sheared, piston seized, rev band not applied, no reverse gear.
During fix #2, a torrington started loosing its needle bearings.
****
My point is not to contribute to the pile of stories but to point out how easy and quick it is to get into the unit and make repairs.
The biggest headache is the dwindling support in the parts channel and is getting worse quickly.
I'm managing my inventory of replacement parts and, for instance, now have two sets of OD sprags on the shelf, two friction kits, etc.
Long term I'm looking to adapt something newer, more robust, better support, 6 speeds.
****
Elsewhere I will (someday) do a couple of write-ups, one on how to very quickly pull and install the unit.
and now consider myself a well seasoned technician.
Current story #1: OD sprag and obliterated frictions as per Zenish link. Root cause unknown, not proven, but I was goofying around with the gear shifter at the time.
Overall tranny health lasted only 4 trip, 15 miles total, leading to current story #2: reverse gear gone. Was due to rev piston not seated properly on rev band during fix #1.
Rev piston shaft bent, tip sheared, piston seized, rev band not applied, no reverse gear.
During fix #2, a torrington started loosing its needle bearings.
****
My point is not to contribute to the pile of stories but to point out how easy and quick it is to get into the unit and make repairs.
The biggest headache is the dwindling support in the parts channel and is getting worse quickly.
I'm managing my inventory of replacement parts and, for instance, now have two sets of OD sprags on the shelf, two friction kits, etc.
Long term I'm looking to adapt something newer, more robust, better support, 6 speeds.
****
Elsewhere I will (someday) do a couple of write-ups, one on how to very quickly pull and install the unit.
Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
whatever is done is not going to be cheap unless you can do it yourself and resolve all issues yourself.
try one of the transmission exchange-rebuilders that advertise on most Craigslist sites. In Florida they advertise constantly.
if you can get the last year Aerostar transmission, it has 4 speeds ( 3 + Overdrive), I forget the model name of the transmission.
Mine has proven reliable since 2013 when I bought the 1997 Aerostar RWD Extended body. ( 1997 was the last year for Aerostar).
try one of the transmission exchange-rebuilders that advertise on most Craigslist sites. In Florida they advertise constantly.
if you can get the last year Aerostar transmission, it has 4 speeds ( 3 + Overdrive), I forget the model name of the transmission.
Mine has proven reliable since 2013 when I bought the 1997 Aerostar RWD Extended body. ( 1997 was the last year for Aerostar).