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I have had very good success with my 93 Aerostar up until now. It has 240,000 miles and has served me well. Just the other day, I ran over something in the road and popped the right rear tire. The next day the starter froze for the first time ever. I don't know if these two events have anything to do with each other.
Today, I took the starter off and had it tested at AutoZone. They did not indicate a problem, except that it drawed a lot of power when they switched it on. I put it back on the van and it fired right up. Then pulled it out of the garage, shut it off, and then it would not activate. Two times it has failed, I tap on the starter with a hammer and it works.
I would definitely replace the starter. If this is the original it is due for replacement as it sounds like it is warn out. I have it happen on a Bronco II & a coiuple of other Fords the same way. Check the cables & solenoid connections also. I would also replace the solenoid as it is also due.
Had a similar problem. One time would start right up next time no. Mine had a loose connection. We found it in the dark when my father was looking under the hood (had just replaced the solenoid) while I hit the ignition and Pop saw it arc. Had to crawl underneath and reattach. Fine since.
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