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I bought my 93 extended 5 years ago with 87000 miles on it. I have loved it since the day I bought it and have had no major problems up until now(165000 miles). A couple of months ago it started clunking when I put it in reverse or in drive. Another thing, when it started the clunking I think it was having trouble switching gears also, now that I look back on it. I would be accelerating and it would feel like it needed to shift and I would let up on the gas and then accelerate again and it would switch gears. When it seemed as if it should switch gears the check engine light would come on and then when I got it to switch gears the engine light would go back off. A couple of weeks ago it started hesitating before it switched gears. Now it has started to do it more often with longer hesitation. I dont know alot about automatic transmissions, in fact I know almost nothing. I never had driven and automatic before the Aerostar. I dont know the warning signs of transmission problems to be able to tell if it is an easy fix or not. I also have this clanging when I accelerate quickly. Someone told me that I need more octane in my gas? The check engine light--is it just a coincidence or does it have something to do with my transmission? Thanks for listening!
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1 of the first things I would do is change the trans fluid and filter if you havent done it. Aerostar trannys need lots of love because they are worth as much as the van to rebuild. Look for dark fluid and when you pull the pan check the magnet for metal. Also lay next to the van in a safe area and have someone put it in gear and see if the 'clunk' is from the trans or a U joint. If it sound like its from behind the trans try to turn the drive shaft with it in gear and see if there is any 'give' at the U joint. If the check engine light goes on and off it sounds like it might just be that the idle is dropping below tolerane. This may just be a basic tune up if one has not been done. I would just make sure the 'basics' have been done before you spend big dollars on the trans.....
Another possibility is something that was discussed here recently. There were some owners with minor engine troubles that manifested themselves as major clunking of the transmission. A simple case was worn spark plugs, or plug wires, causing misfires that would cause the engine to cough or jerk, which translated to the transmission shuddering. Since your check engine light was also coming on, I would tend to suspect that the engine is not running right. Another simple check is to see if you have a vacuum leak somewhere. A number of owners mentioned the tnedency for these engines to backfire, which blows off vacuum plugs. This will definitely cause misfires under load, and can trigger the check engine light.
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