Removal of the transmission in your Ford Aerostar basically requires stripping it of all the electrical and mechanical connections to the engine, computer and driver control mechanisms. And since you are dealing with one of the heaviest components in your Aerostar, you will need to approach your task well organized, use some special equipment and recruit the help of an assistant to secure and remove the unit. This will make your job not only easier but also much safer.
Instructions
1. Detach the negative (black) battery cable using a wrench. Raise the front and rear wheels of your Aerostar using a floor jack and support it on jack stands.
2. Place a drain pan under the transmission pan and gradually remove the front and side mounting bolts to drain the fluid. Then completely remove the pan and drain the rest of the fluid. Replace the transmission pan and hold it just with a bolt at each corner. Use a ratchet, ratchet extension and socket.
3. Remove the small access cover from the front of the transmission, where it joins the back of the engine, and unfasten the four nuts securing the flywheel to the torque converter. Use a ratchet and socket. Shift the transmission to neutral and ask an assistant to rotate the crankshaft pulley clockwise with a socket and breaker bar so that you gain access to each of the nuts through the access hole.
4. Detach the drive shaft connecting the rear of the transmission to the rear axle. Make alignment marks on the rear axle flange and the rear of the drive shaft using a white marker so that you reinstall it in the same exact position. Remove the U-bolts and nuts that connect the drive shaft to the rear axle and then slide it off the transmission. Place a drain pan under the rear of the transmission to catch any dripping oil.
5. Unfasten the speedometer cable from the transmission rear housing or unplug the electrical connector, depending on your particular Aerostar model. Also, unplug and unfasten the vehicle speed sensor from the rear housing. Use a ratchet and socket to remove both components.
6. Start removing the rest of the sensors mounted on your transmission by unplugging and unfastening the mounting bolts. Also, detach any cables and vacuum hoses from the transmission. Tag wires and hoses and store mounting bolts with their respective components for easy reassembly.
7. Remove the wires from the back of the starter motor and remove the starter using a ratchet and socket.
8. Remove the transmission filler tube using a ratchet and socket. Support the engine with two jack stands and secure the transmission to a transmission jack. Raise the transmission with the jack just enough to release the weight off the cross member underneath. Detach the cross member using a ratchet, ratchet extension and socket and remove the insulator that connects to the cross member from underneath the transmission using the ratchet and socket.
9. Lower the transmission a few inches with the transmission jack just to gain access to the oil cooler lines. Disconnect both cooler lines at the transmission using a line wrench and plug the lines with clean plastic sheets and rubber bands.
10. Unfasten the bolts securing the transmission to the engine block using a ratchet, long ratchet extension, socket and universal joint.
11. Separate slowly the transmission off the engine block by pulling the transmission jack with the help of an assistant. Double-check that the transmission bell housing has cleared the dowel pins at the back of the engine and the torque converter has cleared the flywheel.
12. Lower the transmission and remove it from under your Aerostar minivan.
Tags: ratchet socket, using ratchet, cross member, drive shaft, extension socket
