Ford Aerostar :: 1991 - Running Rough / Very Low Vacuum
Oct 5, 2014
1991 aerostar 4.0 ... My van was running well til last week.it allegedly has 77000 miles on it. It started running really rough within a 50 mile period. I've quit driving it til I am sure. I am not harming it. I put a vacuum gauge on it. It wildly fluctuates between 3 and 7 pounds at idle. I've tried plugging the four vacuum lines one at a time to eliminate the accessories as the problem.the check engine light is off and my scan tool shows no codes.i unhooked the exhaust at the manifolds to make sure the cats aren't clogged.it doesn't have egr. There's no water in the oil or bubbles in the radiator.i have a compression tester but id like to avoid trying to get to the plugs unless necessary.
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1990 Ford Aerostar. When I start runs really rough and has excessive fuel consumption and the exhaust smells like gas and has a misfire my friend says its the coil pack going bad im not sure. I love my ford aerostar dont wanna get rid of it.
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My 2005 Freestar (not the Freestyle) a/c is working properly except that it is only blowing through the defrost. I've read other posts about it being a leaking vacuum system on other ford vehicles that cause this problem.
1) I'd like to confirm that this Freestar a/c works on a vacuum system to open the a/c duct doors.
2) If it is, where are the vacuum hoses located? I'd like to check them to see if they are connected or if they have a hole.
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My engine stalls when cold or warm, when put in gear or idling in gear at a stop. If I left foot break and give a little gas I can usually keep it going. I ran 2 bottles of fuel injector cleaner through, but no dice. Could the fuel filter need to be replaced? If so, where is it located? 1991 Aerostar 3.0 Auto RWD
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It would appear as though my steering leak on my 1991 Aerostar is coming from the seal, where the steering shaft enters the steering box. I'm trying the Lucas treatment but it doesn't appear to be working. Can this seal be replaced WITHOUT replacing the entire steering box?
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Searched several times over the winter. Finally tore each hose out one at a time and went carefully over it before returning or replacing.
Turned out to be the long formed semi flexible vac. hose that runs from the gas fumes purge tank control valve group to the throttle body across the top of the engine. Ripped it out, on one of the bends was a small crack all the way thru, apparently would open up wide when stressed and cause problems. Mainly on hill pulls or hard acceleration but not every time. NO hair left after this one.
Replaced, deleted the codes. Runs like a top.
Still amazed at how much power these 4.0L V6 OHV Fords have from low speed on an uphill on ramp drag race.
stirs the old hot rodder blood.
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Where/how to check the ATF in the transfer case? I found the lower drain bolt,but I don't see anything up higher that looks like a fill hole.
'91 Aerostar 4.0L AWD
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Have a 91 Aerostar that won't start. Has fuel pressure, pulse to fuel injectors, strong spark, strong compression, etc.
Thinking that the spark may be coming at the wrong time I tried a spare ignition module that I keep. No luck. Since my distributor had a lifetime warranty I got another one, again, thinking spark was coming at wrong time. Nothing. Engine won't even pop.
I am going to drop the front pipe in the unlikely even that the new converter is plugged or, somewhat more likely, the muffler, but I am leaning toward a computer at this point.. Still don't understand since it is getting spark and gas why engine won't even pop.
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How to remove roof rack on 91 Aerostar? Google and search box here yielded no result so a new thread is likely in order. I have leaky roof. Not windows.
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I developed a freeze plug leak while driving into town in my 1991 Aerostar with the 3.0 liter engine. Got to Schuck's (my destination) and bought some antifreeze, noted where the leak was and filled up the coolant system.
Drove a few miles to the mechanic's house. Coolant blowing out everywhere, obviously boiling off. Let it cool down while going over an estimate for repair. Topped it off one more time and went home. Have not moved it since.
There is sludge, almost like thick foam, that I suspect is what's left of coolant that has had the water mostly removed. It is the same color as the coolant - bright orange-ish green. Will a few flushes with fresh water clear this out of the system?
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Will interior door panels from a '91 Aerostar fit a '96? No power windows or locks. The panels in our '96 are busted and I found a good set in the salvage yard in a '91. Lady at salvage yard says they're different, but I'm not so sure. Also, will the windshields swap?
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My '95 Aerostar 4.0 no longer likes to shift out of first gear. It will if I accelerate to maybe 25mph and completely get off the throttle for a few seconds. (It also revs freely at full-throttle kick down, as though it was in neutral.) A fluid and filter change didn't work, so I dug into forum posts. I found the vacuum modulator, and there's no ATF in the vacuum line, but it's an adjustable one which has me baffled...
The modulator has a thumb wheel on the outside of it. It will unscrew completely - and then it comes off, with a pin attached to it. This is very different from the ones I've seen pictures of here, where the pin is moved by the diaphragm. Is this the same pin, or some kind of preload device for the actual pin farther inside?
There's enough else wrong with the Aerostar that I'm not willing to sink very much more money into it. It'll run as is, as long as I'm careful. I'm just trying to get a few more miles out of it... might a regular, non-adjustable modulator?
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I have a 1991 Aerostar 2wd 3.0. I recently had freeze plugs replaced and the mechanic had to drop the tranny to get to some. Now the shift cable has come off the gear selector lever. I have googled everywhere and can't locate the procedure for reattaching it. My mechanic was doing the work on the side and charged me only labor for his assistant. He is at work right now..
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AC recharge seemed to be when problem started. But... If I do NOT run the AC unit and drive it with VENT open there seems to be no smell. When I run the AC the smell appears. Since the AC system is supposed to be(I think) a closed under pressure system why would I get a gas smell ONLY when the AC is running? Starting /stopping it gets a bit worse. Baffled here but that's nothing new...
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Aero, 3.0 Shorty 1989
put a new radiator in my truck, as the original one finally had a small crack.. (I've kept it, since it is brass or copper!)
I put a new 192 T-stat in there too, (OEM temp)
but, now it seems that the van is running hotter than it did before!
when I had the original rad in there, it would never get above the R in the Normal word... now it runs at about M (high middle)
Also, when I tryed to burp it, I'd top it off, but then it would put the extra in the overflow tank, and only stays full up to the very bottom of the filler neck.
this is a plastic radiator... is that what the difference is?
I used to be able to top off the old tank, and it would be right at the top whenever I opened the cap... not so with this one>?
wondering if I should go down to like a 180 degree t-stat? gauge still stays normal - but if it's correct, it's about 50 degress difference.
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i have a 1991 ford escort pony i w driving it fine all day then all a sudden i stopped to get water the car died when it did i tried to restart it , it bogged out and didnt start i waited a hr it started idled for 20 mins reved it up everything seemed ok but then i went to actually drive it i got 1/3 of a mile if that and it died on the side of the road with my lil daughter in the car and 104 degrees outside. me and my father thought it was a furl filter or pump but in the primer valvei t has plenty of fuel and pressure. what it could be?
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My vacuum pump I noticed is running constantly and also my vents are stuck on defrost.
I narrowed it down by taking off the lines going from the tank to the 4x4 solenoid and the tank to the HVAC line. If I plug both lines I get pressure to both but it still won't shut the pump off. Why won't the pump shut off? Leaky tank?
If I plug the red line back into the solenoid I cannot get pressure to come out of the HVAC line. (Switch in cab set in 2wd)
I can make the pump shut off by plugging the main inlet to the pump.
I took the tank out and can't find any cracks or leaks. Could something inside the tank be broke?
Also why can't I get pressure when the red line is plugged into the selinoid?
I can't figure it out. Almost seems like the 4x4 solenoid and the tank are both the problem.
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Ok, I know I have a vaccum leak. I have manual hubs now and those lines are capped. The AC is blowing through the deforst and the pump is running non stop. I have replaced the vac pump a couple of years ago and it worked fine then. any other places to look?
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I've had this problem for a little while now, my 97' F150 V8 4.6L, has been running real loud and heavy. When it starts up it sounds like a race car. It finally shot me a code for P0171 - Bank 1 (passenger side) running too lean. From what I've read, this is most likely a vacuum leak but I don't know too much about it.
A couple of things I've noticed while driving it around:
1. If you are in the engine compartment while its running, you smell the excess gas on the passenger side of the truck.
2. The exhaust also smells really heavy
3. The loud and heavy running is mainly when accelerating, if I maintain a constant speed at for a little while it almost starts to run normal. Cruising down the highway its almost just as quiet as before the issue
4. Engine coolant heats up much more quickly, but doesn't get above operating temperature (read from tuner, never above 200 degrees)
In response to the problem I replaced both the O2 sensors closest to the engine and the PCV and elbow. No change. Have a fuel filter ready to install, but for some reason I don't think that is it either, as it would probably effect both bank 1 and 2.
Like I said I'm not too well versed in the vacuum system but if any of these symptoms stand out I'd love to hear your thoughts.
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Winter is over and summer is here. Will running with the AWD module unplugged increase fuel mileage? Will it do any harm to the drivetrain? (Assume matched tires, good alignment and suspension).
Signed, Looking to squeeze a buck anyway I can.
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What is the procedure for replacing the fan clutch on the water pump? Mine has a slight wobble when running and I started to pull everything apart but got stuck when I couldn't see how the fan and clutch disconnects from the water pump. It's a '94 4 liter XL extd body...
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