@gaz
I really like the "using a 1st Gen manual column" idea. That is now my hope as I am not a fan of column shifting.
Since I am now planning on the 94 computer/wire non-EGR (Federal) harness for an auto transmission but with a 89-94 gen. manual column, does this open up any options regarding column source years; are the 95-97 manual columns any different?
A "2nd Gen" column will be needed with the '89-94 dash. This gets confusing; the "2nd Gen" interior was used with the 2nd generation body style ('89-'92) and it also carried over into the 3rd generation body in '93 and '94. 1995 got a new dash, the gauge pod being more rounded.
I think that there may be a difference in the number of computer-controlled solenoids between the '87 and '94 A4LDs. Using the '94 host harness would be best, but there may be an extra plug for the trans. You can probably check this in the EVTMs or by comparing the computer pinouts.
While I can't state it as a fact, I would think that the '95 columns are different, as the 1995 model year introduced air bags to the Ranger. That and OBD2 are the main reasons I've never owned one newer than 1994 (please; to each his own).
Regarding Cruise Control issues, will 1st or 2nd Gen columns make a stock Cruise Control challenging?
Cruise would be about the same install-wise, first or second gen column. The ideal would be the '94 donor having the cruise already, and just swap it over with everything else.
Will I need the ductwork from the doner vehicle or can I use the 87's with the replacement dash.
I read something about needing to enlarge the firewall hole for the newer columns, is this a fact?
Sorry, I don't know about these two.
Does this mean that I can broaden my column/dash search to;
89-94 Ranger
90-94 Navejo
91-94 Explorer
89-96 Aerotsar
Or will i be better off using the dash from the doner of the PCM and harnesses?
Add the 1989-90 Bronco II to the list; I'm not sure myself on the Aerostar dash being the same as the Ranger / Bronco II / Explorer / Navajo / Mazda B truck.
In my opinion, using the dash from same donor as the PCM and harness would DEFINITELY be best. You'll know that all of the stuff has already worked together.
Good luck!