I recently swapped engines and trannys out of my '90 Aerostar. Everything went well but now when I go to start it the starter wont release after it starts. I've swapped out starters and starter relay switches and it still continues?

 

maybe your ignition switch is sticking on.

 

CBR900, said my first initial thought. Seems the ignition switch is thinking it is still in the "start" mode, and not the "run" mode, which would be after the engine is started. I would suggest cleaning the contact points of the switch (CRC makes an excellent spray for this purpose) however, the work involved to get to the switch itself, you may as well change the switch, as I beleive they cost around $20. NAPA carries ignition switches for Aerostars. In cars of the 60s, trucks, etc, before the locking steering columns were commonplace, replacing ignition switches was a 20 minute job! Good luck...
PS Try spraying some electric contact cleaner directly into the ignition key hole first. Use a red plastic straw (you know what I mean? haha) to get the spray deep into the switch. Letting the cleaner sit overnight inside the switch, may also help. Maybe you'll get lucky. If this solves your dilemma, then go out and play the lottery!

 

Well guys... Are there 2 different trans for the 3.0? I dont think the starter is staying enguaged I think something is rubbing by the torque converter when it starts? Help!

 

Lose flywheel will make that sound.

 

19felix69:

I know this might be a stupid question but.............Did all the nuts that hold the Torque Converter to the Flywheel get Put On/Tightened?
Also if you didn't get the Torque Converter pushed back on the Transmission far enough and you forced the Trans and Engine together it will make a bad noise.
Plus it will screw-up the front pump.

Jay

 

Was there any shims on the starter, that you didn't put back on? - Not usally a problem with older starter/ flywheels that have worn in, but maybe you need one in there to add some clearance?...

 

Does anyone know if there are different 2 different trans for 90 aerostars. I think maybe the new trans is 1/16 longer when I mount it the engine wont turn free? The motor is from a short van and the trans is from an extended. Are there different flywheels? Any Aerostar parts hero's out there. I've had the trans out 3 times now and cant see the answer?

 

Cancel that, I just checked the vin #'s on both vans and the engines and trans are both the same....

 

Do you have the torque converter bolted to the flex plate when you install the transmission or is it in the transmission?

 

It sounds to me like the torque converter is hasnt went in to the tranny all the way.
When I did mine I thought it was in all the way kid grabbed TC and it spun right in to place. makes a difference of about half inch.

 

Tool clean up comments! SUCCESS... I must admit JTHILL24 mentioned the correct answer back on the 3rd but I finally figured it out yesterday with the old trans....'Yendor' is specificlly correct for anyone doing a trans or engine swap. If you remove the torq converter and replace it like I did it feels and looks (3 car guys I know looked and thought it was all the way in) like its all the way in, and bolts up to the engine. The only way I knew it was wrong was the first time it howls like the starter is stuck. The second and 3rd time I tested it by trying to spin the crank by putting a spark plug socket and ratchet on the bottom pulley and trying to spin it freely. If it doesnt spin relatively easy (there is compression if you dont pull the spark plugs out that will give pressure but if the converter isnt in all the way it wont spin with a breaker bar on the ratchet) The converter should be in an inch which makes putting the 4 converter bolts back on more of a challenge while the engine is installed, but this is a sign that it has been installed correctly. Its a 1 spline difference for it to go all the way in and I only got it right 1 of 10 trys. The 'Ford gods' had it fall in 1 time on the old trans or I wouldnt of believed it was wrong til I saw it! PROPS to all that responded! I couldnt have done it without you guys. I may do a summary later on, for anyone doing a aerostar engine or trans swap, on all the mistakes I made that can come up. I did take some pictures I'll try and post showing the 2 side by side in the garage in this 20 degree temperature we've had here lately in Boise!

 

Thanks for letting us know what you found
The A4LD is one of the harder ones to get the torque converter the whole way in.
We've seen on here a few times where guys have had the converter bolted to the flex plate and then slid the transmission in. That wont work and will destroy the transmission.
It's good that you were patient enough, and smart enough, to fix the problem before you did damage

 

so is a 1991 f150, I messed up a tranny on my f150 by bolting up the torque converter to the tranny first, when I then tried to bolt the tranny to the engine I busted the ears on the tranny fluid pump, $1800 worth.

 

ouch