Ok guys, I need to replace some bushings on the front of my Aero. If I tell the parts guy that I need the upper control arm bushings is he going (or supposed) to give me the bushings that go on the upper control arm where it mounts to the top of the frame in the engine bay? All 4 of them are shot and the control arms are flopping pretty bad in there. I think that is what is making a loud popping noise when I turn the wheel all the way to left and back up.

Did that make sense?

Thanks,
Jim

 

Yes it makes sense.
If that has been going on very long, you may need shafts too, or complete assy's if the Upper Control arm is wallowed out and shafts scored where the bushing rides.

FBp

 

that's exactly what you ask for.....you also might take a couple of weeks at a gym and build up your upper arms......those bolts holding the control arm brackets are a real bear to take off and torque back on.....

 

Oh boy.

Sounds like this is going to be a fun one. Yes the shafts have wallered around in there for some time I presume.Theres pretty much no bushing left. I wonder if I aught to go ahead and get the assembly and count on replacing the whole shebang. I'm going to do ball joints and tie rod ends while I'm at it. Or while the neighbor I might pay to do it is at ..


Thanks guys,
Jim

 

Well if you decide to spring for assy's, go for the Complete Assy's as they come with shafts, bushings & B/Js already installed. IMHO they are worth it. That makes it a bolt in deal instead of pressing out, and fitting, and pressing in, and framming & knocking around under there the whole job. Also nothing is distorted or worn. Plus if you take care of them they're good for another 200,000 miles.

FBp

 

KC8JPZ -
I CAN'T BELIEVE IT !
I just , I mean JUST posted about a clunking that I am getting in my AWD Aerostar. Read my post and tell me if it sounds all to familiar - especially the binding part. I can't see any problems, but maybe I don't know what I am looking fo or have been looking in the wrong area!
Oh well, at least I have new CV joints and axles!
Jim (too)

 

KZ8JPZ-
Here is the post I JUST left - so you don't have to go looking - (I don't know how hard that is as I am a NewBie).

Bind and CLUNK when turning AWD Aerostar

--------------------------------------------------------------------------------
Ok, here's my first REAL post and it is driving me CARZY.
I have a 1991 Areostar AWD 4.0. Heavy clunk in front end, when turning - in reverse it is more noticable. I bought this van with a "bad transmission". Turned out the transfer case was cracked. I drove this van down the street and it CLUNKED when I made a uturn at the end of the street – felt like the wheel was only mounted with ONE lug nut ! . I took the transfer case out of my wrecked van (which drove fine before) and put it into this van.
Still have clunk.
Feels like it is binding just before the clunk. Just replaced the axle/cv joints on both sides. Still have this CLUNK/BIND - reverse or foreward when turning. Seem to drive straight and turn slightly with no problems. I back up to the point of binding (just before the CLUNK) and look at everything - it all looks plumb and perpendicular.
Maybe the Transfer Case control module was bad in this van - which caused the clunk and crack in the old TC housing? I am going to take my control module from my wrecked van and put it in this one. I am hopeful, but.... What else could I be missing? THANKS in advance.

 

pull plug off AWD controller under seat
problem goes away= failure in f/r driveline sensors on top of transfer case, wiring or connectors, usual culprits

still have problem and all symtoms you laid out in original post=do what FordBoypete says

 

Great Diagnostic Tip 96_4wdr!

Ratty control arm bushings eat CV Axles, Crack Light weight, Full Time Transfer Cases, make all sorts of dastardly Noise and Racket going from D to R or N to D or any adverse or reverse loading of a driveline. Pulling away from stop on a hill for instance.

Function of control arms is to control the motion and plane of the wheel's vertical travels while not letting it deflect from that controlled arc. Once front end bushings get weary the control arms will deflect, or allow uncontrolled flexion. So the bottom line as I read it is, keep an eye on my bushings front & rear suspension I will add. You have simlilar rubber & steel bushings in the transmission X Member, and in the trailing arms for the rear suspension and rear drive axle.

It's all about Preventitive Maintenance or PM and frequent Inspection of these components. But keep up with them amd these Aero's are the best kept secret in Autodom when it comes to a practical vehocle that's neat to drive. Not to mention the fact so many go & get so far. Mine is approaching a quarter Million Miles, and for an American Built 1990's vehicle that is sort
of remarkable IMHO.

To check control arm status, jack the vehicle up on jack stands or a lift, high enough off the ground so the tires are off the surface. Then check for movement of the wheels in any other direction than up and down. If it appears to have that, remove the wheel and inspect control arms, bushings, and Ball Joints for excess wear. Always think System. Steering SYSTEM, suspension SYSTEM, Driveline SYSTEM, because all parts of each system depend on the other parts within it to work right.

FBp

 

"Could someone please que the Twilight Zone theme music?"
Oh good Thanks.
Ok, you all know about this clunking binding, in my Aerostar,that I have been trying to solve?
Here is what I did, yesterday (you know what I have done, so far, to the van):
I raised the van up, by the frame, wheels hanging. I tried to rock the wheels back and forth and up and down to find any slop, clunking, etc - None found.
I then decided to pull the control module from under the seat of my old van and put in this one.
Put the van back on the ground, drove it around and NO CLUNKS !
Put the ORIGINAL control module back in AND STILL NO CLUNKS !
"Twilight Zone music more pronounced now, please...thanks"
So, tell me, Gurus - What Happened?
The "jury is still out" on how long it will last, but I drove it - zig zag in foreward and reverse for at least 10 minutes yesterday - with not even a hint of the dreaded bind and clunk.
I will be SURE to post if it happens again.

"Fade out Twilight Zone music..."

 

the transfer case sensors when failing will often be intermittent

my last ones only caused problems in wet cold freezing weather,
just when i needed the AWD to work correctly

 

Ok,
These sensors could be responsible? Where are they located on/in the transfer case? How many are there? I will pull them off the old TC and try them out on this van IF it starts doing this again.
BUT WAIT ! This transfer case came from my old van that was not binding or clunking.
I faintly hear the Twilight Zone music still in the background...

 

can also be wiring and connectors...corroded or damages
tore my last set off with brush on logging road

sensors located on top of TC...one over each drive shaft

 

Thanks, I will check it out.