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Hi, I have a 1990 AWD Aerostar parts van with all AWD parts except rear drive shaft. How much work is involved in making my 1992 2WD sport AWD? Is it even possible? If it involves changing more than the t-case, driveshafts and obviously front diff is it worth it. Putting my 1992 engine into the 1990 AWD is not an option.
Thanks, 007BRONCO
The entire front suspension on the AWD is different than the standard version. You would need to unbolt the front cradle from the frame and replace it with the AWD version. The transmission in the AWD has stronger internal components than the 2WD version so that would need to be changed over as well. Then, there is the matter of the wiring harness and electronic controls for both the AWD system as well as the EEC (electronic engine control) system that requires changing - particularly if you are going from 3.0L to 4.0L.
It would be a lot more work than just swapping major components but then, hey, if you've got the time and patience anything can be accomplished when you put your mind to it. I'm sure the guy who proposed the first Bigfoot truck received similar discouraging advice but he perservered.
I guess my two cents would say... plenty of (silly, imho) ppl trying to get rid of their gas guzzling aerostars here in Canada - see them forsale on about every street corner these days - can steal them for real cheap. My plan is when my tranny goes I will just buy a new used aerostar - I'm going two-tone next time.