Ok we got this van for free, typical 1992 aerostar with a 4.0, broken key in ignition, engine was in need of a major tuneup, overdrive doesnt work, driveshaft was broke, and exhaust was rusted out. Fixed the ignition lock, no problems, full tuneup, got a new driveshaft from j-yard. Found out the muffler on the aerostar was some junk universal crap was so wide it literally over time cut thru the driveshaft. Replaced the exhaust with the correct ROUND muffler. Then we had to drop the trans pan, to replace the 3-4 solinoid and OD solinoid since we didnt know what one was bad and we had the parts and said what the hell and replaced them. Had to put in about 5 quarts of trans fluid to refill the trans. Trans didnt engage at all at first. We were like oh man should of left it alone but couldnt had no overdrive. So van warmed up. we kept going to each gear and the trans started to engage. each gear got better and better. Once van was warmed up van went into all gears no problems. We were like cool, no more problems. Well we drove it around a bit, took it up steep hills, goosed the gas abit to see if down shift worked correctly, took it up to 45- 55 to see if OD engaged. Well it did. I gave the free van to my brother he took it home, went out to start it in the morning, same problem with slow engagement. once warmed up it was fine. No slippage when it engages just takes awhile to engage. THen i talked to him on MSN messenger today and he said he came off the highway and it stalled when he stopped. Bad converter? Seems the converter is not unengaging. Cause the van started right back up and drove fine. We are thinking bad Converter, since we dont know how long the person who owned it before him drove it without overdrive. Before fluid change and replacement of the solenoids, trans engaged without any problems in all gears. ANy comments? its a mystery to me and him as well. Maybe a adjustment for the clutches? Any advice would be helpful.

 

I would put another quart of Transmission fluid in 1st and see if the problem goes away.
That's what it will do if it's low on fluid. I would also check the rear trans seal to make sure it's not leaking fluid out.

Jay

 

Derf750:

Welcome to the forum. You will find a lot of helpful and unsolicited advices here OK, that said, here is one unsolicited advice. Do as Jay said, put in a little more fluid and also check your modulator for a broken diaphragm. Pull the vaccum line on the modulator and check for fluid in the line. If it's ther, the diaphragm is broken and the modulator must be replaced.

It might be good to check the electrical connectors to the solenoid again and make sure it's tight. If it still stalls, I would say you are right and the Torque converter is not releasing.

Good luck

 

ok if worse case scenario if converter is not releasing so that tells me, converter needs to be replaced?, or am I looking at having to drop the trans to rebuild, or is it something internal with the trans. I will check the modulator for trans fluid in the vacuum line. Add another quart which will make it 6 quarts now. Hope thats not over filling that. Like I said already added 5 quarts. But if I have to rebuild it, lol told my brother better have a free weekend your helping me.. Ill post and let you know if it was low fluid or possible bad modulator. I didnt think about the modulator. See its always the simple things we all overlook. Ill keep you all posted.

 

Ok added almost a quart, trans works great now. But now 2 days in a row after it sits overnite in the morning its hard to start. tap the gas it fires.... engine light comes on when he let off the gas and then went away when he pressed on the gas. If it isnt one thing its another... Any comments? Were gonna pull the codes and see whats going on. Maybe that will surface some answers..

 

OK, one thing at a time. It's an old van So the transmission is OK now I suppose. Try to pull the code and tell us what it is. If it sits overnight and is hard to start, I would suspect fuel problems.