Aerostar 4X4

[Hopman]

YUP! You have succeeded in making me want an Aerostar (pinching self...did I really say that?)

Only if it has a 5-speed and looks like Rulebreaker's ride!

 

[86 slo-vo]

love it, but i would have to chop it

 

[Rulebreaker]

 

[feellnfroggy]

That thing def dont belong where it is, it looks so photoshopped it aint funny lOL. I know its not, Ive seen your wheeling pics, but damn. LOL

 

[MountainMike]

So when are you building a pre-runner van?

 

[Rulebreaker]

Sweet

 

[doorgunner]

tell me again what happened to the side window.........

 

[Rulebreaker]

tell me again what happened to the side window.........

3 trees = 3 windows

 

[country0001]

Sweet, totally sweet.

 

[Bugzuki]

I am looking at doing something like this. I have a 1993 Aerostar AWD. I have a 99 Explorer that I will be using. It started out as needing a new engine and progressed into also wanting to get the larger brakes and fix the rearend squat.

So, the way it is now, I am going to use as much of the Explorer engine/tranny and running gear that I can. It has the SOHC engine so I will be using the wiring and OBDII computer and everything else I can.

Now that you have been using your van for a while, can you give any pointer or things you would have done differently?

How are the Aerostar chassis/framemembers holding up in the back where you attached the rear axle?

I probably won't be going as high as you did. Mine will still be the family daily driver/grocery getter. But, I will use it to go camping other fun stuff. Hoping to get 31" tires on it.

 

[Rulebreaker]

I am looking at doing something like this. I have a 1993 Aerostar AWD. I have a 99 Explorer that I will be using. It started out as needing a new engine and progressed into also wanting to get the larger brakes and fix the rearend squat.

So, the way it is now, I am going to use as much of the Explorer engine/tranny and running gear that I can. It has the SOHC engine so I will be using the wiring and OBDII computer and everything else I can.

Now that you have been using your van for a while, can you give any pointer or things you would have done differently?

How are the Aerostar chassis/framemembers holding up in the back where you attached the rear axle?

I probably won't be going as high as you did. Mine will still be the family daily driver/grocery getter. But, I will use it to go camping other fun stuff. Hoping to get 31" tires on it.

Sorry I didnt see this sooner, I never got email notification for some reason. Getting the D35 under the van will probably be more work than it's worth. If your only running 31's you might be able to build a lift block to put between the frame rail and engine cross member to clear the 31's with the stock front end. Be easy on it as there just isnt any beef there. The stock rear suspension locating brackets are still in good shape.

 

[Rulebreaker]

The BroncoStar had a tough year. I winched it in the garage as the fuel system was frozen (water must have been to deep) . Steering box is all but ripped off the frame rail, and something in the front axle is broken so she is only a 3 wheeler right now. I'm debating on my winter plans for her and would like your input.
1st issue.
The front axle could be fixed and run again but I have the option of putting in my Dana 60.(I would have to run it open as I wouldnt have the coin for a locker right away) I even have a set of 15" 8 lug rims that my or my not clear the front brakes. I'd like to lighten up the 60 if I put it in as I believe it may be a little heavy for a 5000# Aerostar. The 60 already has 4.11 gears but it would need to be converted from it's dually setup to a single wheel setup. I wish there was a way to run D44 brakes and 5.5 wheel pattern on a 60.

2nd issue

If I put in the 60 the added weight will make it almost a necessity to pull the 4.0L and drop in my 1967 289 V8 laying on the floor. I dont have the money to EFI it unless I could make the 4.0L EFI run it. I'd probably be ok with the small truck avenger carb and a new distributor. This would make for some serous body work to clear the larger engine and then the question will be can i keep it cool with the stock radiator or will I have to figure a way to put in a larger radiator in a space that I had to modify (due to the steering box) just to keep the stock one in there.

So what to do is the question?

 

[jperry7783]

Dana 44 brakes on Dana 60

This guy doesn't have a normal 60, but if I'm following correctly he has 60 knuckles with 44 brakes and bolt pattern.
http://www.pirate4x4.com/forum/showthread.php?t=420834

Hope this helps

 

[Rulebreaker]

Found the issue with the front axle.

Fix it or 60 it?

 

[Bennybooster]

60 it!!! 44's!!!!!