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I have a 97 Aerostar, V6 4.0 liter. We just bought a new camper, a 21 foot Kiwi. Dry weight is about 3500 lbs., but I figure we're towing probably about 4300 lbs. with our whole family in the van and packed to go camping. Any thoughts about how well the van can handle this sort of weight? It occasionally gets down to 45 mph on the interstate if we have a big hill. We wonder if we're drastically shortening the life of the transmission. Biggest problem: we have to back up a short, steep driveway with a turn in it. We can't get any speed up, so it's backing this trailer up from a virtual stop. Last time I did it, we were literally standing still, not moving at all, for a few seconds--and the wheels weren't spinning. This bothered me just a tad. Oh, this has electronic 4-wheel drive, by the way. Again, I'd welcome any thoughts on this situation. Thanks!
Weight is one thing, but another consideration is the frontal area of the trailer. A trailer with a big area (regardless of weight) will add a big aerodynamic load which you will feel where it's flat. When you come to a hill, it's a double whammy - weight and aerodynamic load. The 4WD Aerostars have the 7.5 inch rear so you also need to pay attention to the load on the axle in addition to total load. (This is true for the 8.8 inch rear but more so for the smaller 7.5 unit.) The 7.5 inch rear doesn't seem to be the most robust, but I think Ford used it in the 4WD Aeros because the engine torque is split between the front and rear axles and they thought they could get away with the smaller axle.
It sure sounds like you're exceeding the towing capacity of your Aerostar. As to whether it will shorten the life of anything, that's hard to predict. It all depends on how often you do it, temperature, how you drive, etc.
You shouldn't have any problem towing this setup. I tow a 21' all the time and haven't had any problems related to it. I really think though that the next time you're loaded ready to go, find a truck scale and drive over it and record your weights. I think you'll be shocked. This will help you to balance your load as well. Little things add up quick. Hope you have a weight distributing hitch and a sway bar. Also, make sure overdrive is off when towing. I also don't believe a tranny cooler is necessary. After crossing the Rockies twice, I had my fluid changed and it was not only clean, but still red (vs. burn't orange), and no burnt odor. Ford tech. was impressed too. Maybe something to be said for Mercon fluid? Don't like the sound of your driveway situation though. Sounds like a good way to eat up tranny bands. Whatever the case, just use common sense and your setup will suit you well.
We had a 93 Aerostar that we towed with. We towed a 22 foot trailer with a 3500Lb dry weight. The 93 Aerostar with the 4.0L and the 3.55 rearend was rated to tow 4800Lb. I did have a oil leak in my rearend and had to rebuild due to burn't bearings at 100,000 miles. I may have run it hot due to the low oil while towing. Check what rearend you have. If you only have a 3.27 that will make a difference in pushing the trailer on the hill. Other than the rearend we had no tranny or engine problems in many thousands of miles of towing and traded it with over 160,000 miles on it. The Aerostar for 93 with a 3.27 rearend and no towing package can only tow 3500Lb.
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