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Just had the '92 aerostar towed home. It clicks, but the starter just won't turn. Headlights are strong and when we tried to jump it from the tow truck, it still wouldn't turn over. I am sure the battery is ok. Sound like the starter to you guys? If so, how hard of a job is replacing the starter? Thanks.
Sounds like a starter to me, if your engine is a 3.0L 2wd it's really easy, did mine in about 15 mins. (I was motivated by very cold weather, no heated garage, and a need to make it run again)
The starter was pretty simple. You will need 13mm socket(pref. deep). Open end wrenches will take longer. Be prepared to strip the small solenoid wire and splice it into the new supplied butt connector. Make sure you disconnect the battery. Ramps are ideal for this job. Hope this helps anybody else that is attempting the job.
If you need to hit it with a hammer, it might be time to lot into puchasing a new set of brushes for the starter. If you let it go too long the starter will leave you stranded.-jc
If you have a 4.0L with E-4WD, it's a bit harder since you would have no clearance to pull it out. You end up having to disconnect the front drive shaft from the front differential to move the driveshaft out of the way. Even then, it ain't pretty. For the 3.0L, yes it can be done fairly easily. Did mine in the McDonald's parking lot