I have a 92 Aerostar XL 3.0 that I have owned for about a year and a half. I bought it at a 'hoopty' auction for $800. I've invested about another $800- 1000 in routine maintenance/failures. Repairs include tires, steering joints, hoses, belts, heater core, and rear end seals and gaskets. The van runs really good except for the occasional rough idle (more not smooth than rough). I need some advice about the A/C system. A while back I started hearing a terrible whining noise from time to time coming from the engine. I found later this was the A/C cycling on while defrost was selected. I suspected the van would be out of coolant but didn't think it was a big deal because I wasn't running the A/C. Now, I realize the A/C cycles periodically and I was thus damaging it. As a temp fix I just unplugged and bagged the A/C connector. (Summers in Wisconsin without A/C aren't a big deal.) Now, I have moved back to Kansas and will need A/C. I'm assuming I've trashed the A/C compressor and I'm sure it will need converted to R-134. How much money am I probably looking at? Also, with close to 170k miles is this worth doing? The engine seems strong now but will the added effort of powering the A/C be too much? Although the van just made two 850 mile trips in a year with no problems, it is mainly a short distance driver (a few miles a day max). However, if need be I need the van to be reliable enough to take over the 30 mile each way commute I have to work. Thanks for your insight. Also, I live in the Wichita area so feel free to recommend a mechanic. I promise not to hold you responsible if I don't like the mech.

 

Yep, that sounds like your A/C Compressor just bit the bullit. I would do a search at the boneyards for a low millage post 93 compressor for your engine. Should not be too tuff to convert.

On my SHO last summer I converted it to R-134A and here is what I spent:

A/C Conversion Kit $35 (Wal Mart)
Compressor $80 (94 model Junk Yard)
A/C Leak Detection Kit $15 (Wal Mart)
2 Cans of extra Freon $12 (didn't use, but just in case, Wal Mart)
1 Can of Dye Freon $7 (walmart)
1 pair of gloves $4 (walmart, don't want to freeze your fingers off!)

Total= $153 and about 5 hours to pull, replace, and fill. Now I have ICE COLD Air.

You can take it in and get flushed for a nominal fee at most garages. If there is still R-12 in the system you can get some $$ back.

Some will recomend replacing the Low/High pressure hoses because they tend to rust and will get metal buildup from an exploded compressor. But if their condition is good, don't worry about it.

 

What you say sounds tempting but I thought I needed a license to do A/C work. Also, I'm not much of a car guy but I am learning. I do work on aircraft for a living so I have mechanical aptitude but no experience with cars and I find that car manuals, unlike aircraft manuals, are written for the expert not the novice/intermediate. Do you know where I can get the procedures for doing all of this? Pictures are the best, of course.

Thanks for the help.

 

Look under AC in the forum, There is tons of stuff in there for convertions and how to.

 

jpete9803,

You do not need a license to work on R-134a system (your own) but you do need one if you hope to buy any R-12 (and now days it is not really worth the price.)

As for a guide, check the A/C forum for diagrams. But if you want a manual I would look for the Ford CD or print manual on e-bay.

Also, with the conversion kit I got from wallmart, it included a CD-Rom that goes in depth on how to replace the items and what items are what. If you can work on aircraft hydrolic controls, replacing the A/C will be a piece of cake.

 

I have a 92 4.0, with 146K. I bought the van a few months ago. The Air seems to work well, but I do not know if it was converted. Does the conversion kit work on an older compressor, or do you have to get a newer compressor?

 

Yes the conversion kit will work with the old compressors. Usually you convert when the compressor blows chunks. To tell if it has been converted look at the connectors on the high and low pressure lines. If they look like tire valve stems then it is still R-12.