How is everyone? So, I don't actually own an aerostar, but have thought about the possibility of one for my next vehicle. Here's my question - this is just something that occurred to me, would it be possible to use the manual 4x4 transfer-case from, say, a ranger in an aerostar, in place of the electronic 4x4 system in an aerostar? I was just wondering, because I thought it would be awesome to have an aerostar that had a strong 4x4 drivetrain for like mild off-roading. Is the concept even remotely possible?
Andy

 

I've thought about this for my Aerostar since I would like to be able to select 4WD when I want it, not when some computer wants it and hopefully save some drivetrain wear and tear as well as maybe even get better mileage. Also, I tend to prefer simplicity over sophistication (except for my wife who is anything but simple). Anything is possible, it just depends on time, resources, patience and money. I'm not sure that the transfer cases from Rangers and Explorers are any stronger than the Aerostar's.

I've looked at the 4WD Ranger and 4WD Aerostar (I currently own both) and it appears that the transfer case bolt patterns are the same and that their locations are the same, or approximately so. But one of the biggest problems would be putting manual (or unlockable) hubs on the Aerostar. Not sure how that would work, the Ranger and Aerostar axles are quite a bit different and I'm not sure the splines are the same. But, I suppose you wouldn't have to change the axles, in which case you would be driving around in essentially the same condition as having the hubs locked and the transfer case in 2WD. I thought the ability to unlock the hubs (not just disconnect the drivetrain at the transfer case) would have been one of the most desirable things about putting a manual transfer case in. The other downside is that, with a manaul transfer case, you couldn't drive on pavement in 4WD.

 

As long as you confine off-roading activities to the "mild" range, the current setup should be up to the task. The uni-body construction, rather than the transfer case, is the weakest link in off-roading in an Aerostar. Plus, that small wheel/long wheelbase configuration high centers more frequently than one would expect. (Trust me on this one.)
As Mikeman pointed out, in the end a change over leaves essentially the same options as you currrently have. This being so, a simple electrical bypass switch to power the transfer case electric clutch on/off when desired would be a far simpler method of selecting 4WD when desired. The downside is the enhanced wear and tear on the clutch pack.

 

I have a thought on this thread, though I do not know that it would work, I am reasonably sure it would. First of all I am a sales manager for a large RV dealership in Florida, and almost (over 90 %) of the customers who own class A motorhomes tow a car behind it. One method of towing a rear wheel drive, automatic transmission car, is a system that disingages the drive shaft. We, install many of these systems in our service department. So the thought is, applying the system to the front drive shaft, and disingaging the drive shaft for normal highway travel, and ingaging for off road. The company that makes the system makes it for all cars, and I am almost sure that they would have one for the Aerostar, though perhaps for the rear driveshaft on 2wd models. M'mmmm I wonder if they have one for the front driveshaft. Anyway it is a simple solution for the problem. By the way the drive shaft is disingaged from inside the car, with this system. if you have any questions about this just ask, I'll try to get the info.

 

Forgive me, like I said, I don't own one. But, could one just change the transfer case and everything forward of it over to a Ranger setup as well, or would that not work with the Aerostars steering system, or something? If it would work, were Rangers ever put out with automatic/self locking (whatever they're called) hubs? Sorry guys, I'm really new to all of this, all I know about vehicles is small FWD cars. Also, are there any actual Aerostar websites? I haven't found any as of yet. I've just resently taken a real interest to them, my parents used to own one, and we all loved it. I would like one as kind of a project... My ideal one would be to combine the 4.0L, a 5-speed, and traditional 4x4 system. Not yet sure if any of this is possible. Thanks for humoring me though. Anyone have more ideas?