For any of you who have an alternator go on you in the aero, it is VERY easy to replace. I learned this the hard way, having the Aero get stuck at a truck stop because of a dead alternator, on a Sunday, in the middle-o-nowhere, GA.

You just need a good socket set (metric and standard), a few screwdrivers, a can of wd40 and the replacement alternator (got mine @ pep-boys, $120 for a rebuilt $50 core). It took me 2 hours (half an hour of which was adjusting and readjusting the belt so it wouldn't whine or slip).

You need to take the air hose off, as well as the oil fill neck (makes things MUCH easier, but not exactly necessary), it would be a good idea to mark on the tension adjustment bolt where the proper adjustment is on the threads with paint/white out to speed up readjusting the belt. It also helps to have an extra set of hands in getting the long mounting bolt back through the holes (lining up the holes and pushing the bolt in at the same time is annoying). Use WD40 on all the bolts you put in and take out, it makes life easier. Lastly, the rubber boot on one of the alternator wires (the one with the loop terminal) can be tough to get off on high mileage cars, just take your time.

Thought I would add my experience to the Aerostar knowledge base.

 

If I am in the shop, I go through the wheel well with a 3/8 impact to break loose the lower bolt. Definately remove the air intake tube. Replace the harness that plugs into the alternator, the problem with shorting is real. Most warranties will not apply if you don't. The paint or tape on the tensioner bolt is a good idea. I usually use an educated thumb though.

 

Great info! Thanks guys. I'm going to be trying this either today (if it stops raining) or tomorrow. Helps to know the little tricks.

Haley

 

haley,

Make sure you get a "good" alternator with decent specs according to the test sheet that came with it. I had to replace the alt in my '97 and got one that had poor performance at idle as disclosed on the test sheet. The next one, same model and manufacturer, clearly showed that it had higher output at lower RPMs. The auto parts place understood and was very willing to let me have the "better" alt...

DadVan

 

In replacing the alternator, see if you can replace the four voltage regulator torxs screws with small hex head ones. That way one might be able to remove the voltage regulator without having to remove the whole unit (never tried it, but I think it will work). You'll still have to stick a paper clip thru the bushes to clear the way for installation.