We are looking into getting a 4.0l AWD extended Aerostar (Don't have a specific one picked out, just looking for one). However, for the type of things we would use it for, a manual transmission would be preferable (lots of towing). I was wondering, would getting the electronics and transmission with transfer case be a good idea, or are there fit related issues. I was thinking of getting the parts from either a Ford Ranger or a Bronco II. Any suggestions would be welcome.

 

I don't think an Aerostar with a 4 liter engine ever came with a manual transmission. It's a matter of the transmission not being able to last under that kind of load, let alone with 4wd. What kind of manual transmissions are used in Explorers or Rangers?

If I were to do something like this, I would just hook up a manual switch for the clutch.

 

Perhaps I didn't phase that as well as I could. I am well aware than the 4.0 Aerostar never came with a manual transmission. What I want is to take the manual transmission systems from a Rnager, or some other Ford in the light duty department. I know the Rangers used the same transmissions as Aerostars. If the transfer cases are the same, I am figureing it would be posssible to just pull the parts off a donor vehicle, and transplant them to the Aerostar. Has anyone ever considered doing this? Anyone have any ideas if it will fit? I would imagine that an opening would need to be made for the shifters to come up through the floor. What I guess I would really need to know is if verything would bolt and match up besides that. Obviously I would need a clutch too. All thoughts are welcome.

 

Aero has different unique transfer case, Dana 28
http://www.drivetrain.com/dana28transfercasesillust.htm
not used in any other Fords and no longer made
pricey to rebuild compared to heavier duty units in other Fords

possible to DIYer a Ranger or Explorer tranny/TC into an Aero with major TC mounting and drive shaft changes....i would go with a manual control TC and not a full time automatic unit that requires the dedicated controller, early '90s Ranger should fit the ticket

 

Just a note...when we had our first van, it was a 3.0 shortie with 5-speed. At one point, the tranny was doing some really odd things (but magically sorted them out itself), so I was looking at possible replacements...I found out that for the 5sp tranny, the case was diferant between the ranger/explorer and the star...the shifter bolts in farther back toward the tail on the ranger/explorer unit. This would definately require cutting a new hole, and may even put the shifter in a location where it would be virtually unusable...

Just a thought...

The early model Mazda built 5-sp used in the early stars until about 88-89 IIRC was actually a direct swap, as it had some type of odd "converter" thing on top, that moved the shifter pick-up point closer to the front. The later models were a totally different tranny, and did not use this adapter - nor, do I think, if one was found, could it be used for the later model trans, either...

 

K, well guess that answers my questions. I'll stick with the Auto unless I found an older 5 speed Aero.

 

khantyranitar! I have manual tranny, A4ld was before. I have no problem with electronics (89 code dissapeared, when I connected 2 resistors instead of auto tranny valves), and idle if a bit faster. Runs faster!

 

What tranny did you use? Was it from anothe Aerostar? Does it have 4 wheel drive?

 

I have Russian 5-st tranny (from Volga). I have 2wd model, but there is enought room for transfer case (to add 2 shafts). I wanted to install it, but it was a car accident last year, and I had no opportunity to get x-member from AWD model, so I have only one modification - dual drive shaft. With 5st aero may easily run 100 mph, and I had vibrations with original shaft at 90 mph.

 

Kan! Tranny of Mazda E2200 fits aero too. Transfer case (but mechanically controlled is availible too). As I remember this tranny is used on Rangers!

 

If you are going with this then get a 4.0 5 speed and transfer case from a Ranger.

 

Gentlemen,

With all the incumbent problems of this powertrain swap, I would lean towards the manual control of the torque converter clutch. In my 4.0, towing up a hill causes the trans to drop into second and the tcc unlocks sending the trans temp through the roof. The trans seems strong enough but the tc causes overtemping when unlocked.

This manual control of the tc is something I want to explore. Which wires control tc lockup?

Ken

 

Ken! I tried to use manual control of TC, but it locks at OD ore 3-rd gear only. There are special vaves in the valve body, that prevent TC lock on 1st and 2nd, if the signal comes to TC lock valve. And if you try to turn OD on, it is possible if 3rd gear clutch is locked too. To change shiftings regimes is possible by replacing spring and conterweight of governor.

TC clutch - whight wire
OD clutch - tan. lt. blue
RED - +12 V

 

I don't see any reason that you couldn't buy an M5R2 transmission for a 4.0L Ranger and swap it in. I think that the D28 transfer case should bolt up to it, I think that Ford used the same 4WD A4LD in the Aerostar as they did in the Ranger and Explorer, so if t-case for all 3 bolt up to the A4LD, then they'll bolt up to the M5R2.

I've thought about this swap too, but decided that since I wanted to tow with my van, the auto was a better choice (the manual Rangers have pretty low tow ratings). But you should be able to pirate the trans from a Ranger, the pedal assy from a 3.0L manual Aero, then you'd just have to figure out the shifter placement.

 

Some my frieds swap trannies, but there is no one aero with tranny from mazda here, in Lugansk, one aero is with Ford 5-st tranny (from Transit), the other is with Tranny from Mercedes 610D (very good tranny!), my aero has tranny from Volga, but I'm absolutelly sure, manual is much better for towing. With this trannies t-case for permanent AWD is not used. FWD activates manually ore automaticly if rear wheels skid, but as I remember with A4LD t-case for permanent assimetrical AWD was used (70% - rear axe, 30% - front), in case of skidding t-case lock activates.

But as I can see, there is a lot of room under this van and it is possible to install any transmittion and transfer case. To make driveshafts is not a problem too! So try to use trannies for good torque (250-300 n.m.), try "slow" rear ends (3.9 ore 4.1 ratio). I can post some photos of aeros with different trannies. But IMHO, it is more difficult to find a good reliable clutch. In my van clutch - is collection of 5 brands (clutch disk is from Mercedes, pressure plate - VW, hydravlic parts - Lada, flightwheel - Volga....). Clutch from ranger overheats and goes out under the heavy conditions, especially in deep sand ore snow, when vans gets in stuck. So pay attention to clutch. I know there are many firms in The USA, that offer perfomanse parts, and I belive it will not be a problem to purchaise good clutch.