Help Pre-build advice

[whynotthinkwhynot]

I have 92 Aerostar that I use for my business. We haul ladders and some material, so you can expect about 600 lbs on the van at any given time minus passengers.

The old flat tappet 3.0 gave out on me the other day, and needs a rebuild. I have a roller cam engine from a Taurus which I believe was an FFV vehicle. From what I understand I can transfer parts from my engine to this one to make it work in RWD. I plan on a full rebuild, so the head gasket difference is not a problem.

The main problem with this van is that it lacks power. It always has even when it was running right. I'd like a 4.0, but finding an Aerostar wiring harness for that engine is a problem. If I can do it, that would be the best way to solve the power problem IMO. Yeah, I know I'd need a transmission, mount, and crossmember as well.

Ok, so if I'm stuck with the 3.0, what would be some recommendations? The ECU is a MAP sensor not MAF- which is good in some ways. Some of the things I don't know that I'd need to know:

1) Do Rangers have a driver's side exhaust manifold with the oil dipstick going up through the manifold between the runners on 4 & 5? I'm trying to figure out if I can use shorty headers.

2) StuffforyourRanger mentions that the roller rockers require tapping the head for studs. I assume this is to convert to SAE so you can use locking nuts for adjustable rockers- is this correct?

3) My 97 Aerostar 4.0 has a DIS run off some device that fits where the distributor fit. Did later model 3.0's have this same setup, and can it be made to work in an earlier engine/ECU with some rewiring?

4) What's the largest TB I can fit on a later model intake manifold, and what year model should I be looking for?

Thanks, I'm still not sure what's going to happen to the van. A motor is cheaper than a new van, but then I'm still in an old van. Sadly, rebuilding the flat tappet block is likely not going to be an option. I'm fairly certain the rings have been ripped off, and it would be cheaper to use the roller cam block than rework the old one. I'll know more when I get it out. To make matters worse- I don't have a lift. Aerostars are no fun to replace engines without a lift.

Thanks again for any help!!

 

[whynotthinkwhynot]

OK, so no advice?

 

[Earl43P]

http://www.explorerforum.com/forums/forumdisplay.php?f=146

Sorry I can't be of any more help than that. They do have a pretty dedicated following over there, but it's not the most active part of that BB by any means.

 

[Ranger44]

With a 3.0 gearing is VERY important. The engine is a rever, but reliable as hell.

What gear ratio is in the rear now?

If it's something like 3.55's, then a bump to 4.10's or so will yield some "power".

 

[Donnie strickland]

http://www.explorerforum.com/forums/forumdisplay.php?f=146

Sorry I can't be of any more help than that. They do have a pretty dedicated following over there, but it's not the most active part of that BB by any means.

Aye, the moderator of that forum, BrooklynBay, is the MAN when it comes to Aerostars. He's very helpful and I bet he can answer all of your questions.

 

[whynotthinkwhynot]

That is a great help, thanks guys!! You have a lot of good information on the 3.0 here, but I can't get Fred to answer me about the 5.0 roller rockers that he sells on stuffforyourranger. I'm hoping that I won't have to tap the heads to use the adjustable nuts, if so, I'm wondering why I wouldn't just order a set of Pro-form adjustable roller rockers for a 5.0 instead and have 4 left over.

I love these dadgum vans- have owned 3 so far, but my partner is wary of the condition of the work van because it died 2 weeks after I did a head gasket job- the rings ripped off, 286k miles, I knew I was taking a chance when I didn't do a full re-ring job, but we couldn't afford it- and the compression was good with a new head gasket. Just my luck the water pump and fan clutch went out on the highway.