This is my first post here. All I want is some virtual "pats on the back" and some "man, I’ve been there too". I did the biggest job I have ever done.

1988 Aerostar. Heater not working well, had coolant smell at times. Defrost position totally ineffective, resulting in no defrost last winter. Decided it needed to be fixed this summer - or trash the van, it was essentially useless in the winter.

Took off dash top panel, discovered the heat/vent door not changing positions - stuck in the vent position. When in the vent position, the heat/defrost door essentially does nothing. Wasn’t the vacuum motor, it was the plastic plenum chamber door not working.

Ford discontinued the heater plenum chamber long ago. Tried several wrecking yards - no go for that part. Bought an entire 1989 A* - AFTER confirming all heat/vent/defrost functions worked.

Decided to replace entire cooling system - water pump, heater core, radiator, for preventative measures. In for a penny - in for a pound. Removed seats (for maneuvering room), entire dash, heater plenum, fan motor assembly (inside engine compartment). Man what a job.

Carefully cut away dash in 2nd A* dash to remove heater plenum assembly - kept the 2nd A* running since the driver’s side of dash was still in place. Cleaned plenum assembly - doors and vacuum motors worked like a charm.

Removed all AC components, except for compressor - it acts as a pulley. AC wasn’t working anyway. Cleaned/fixed/rebuild every thing related to the job, using best parts from either vehicle. Also found that old heater core was indeed leaking.

Reassembled everything. Reconnected every electrical dash connector. Turned key - ENGINE STARTED. Air flow MUCH improved due to AC core being removed. ALL heat/defrost/vent functions work excellent!

Two twelve hour weekends and several four hour nights and all is back together. Got to love a successful outcome of such a job.

Thanks for the read.


Dave

 

Dave, you are a man among men here when it comes to us Aerostar owners! Good job! Very much impressed, and I will save your post for future reference. I nominate you for "Aerostar Owner Of 2005" award. Bill Ford (of Ford Motor Company) will present this award to you, sometime in December. Ed

 

Nice job. Glad it had a happy ending.

 

Great job.
wore me out just reading all the work done. been in and under that Aero dash too many times, a pain in the back and elsewhere.
enjoy the defrost this winter, you earned it.

 

Welcome!

Glad to see that you were not a wuss and took it in to a repair shop or steelership to have it fixed! Enjoy the heat in the winter and summer!