Ford Aerostar :: 1995 4.0 No Longer Likes To Shift Out Of First Gear / Vacuum Modulator Oddity


Mar 20, 2011

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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About 2 weeks before I found the problem I notice the van would not kick into overdrive. When I finally found the issue and reconnected the hose the trans shifted fine but still would not kick into overdrive though. Is there another vacuum hose that goes to the main vacuum housing? or an adjustment on the linkage area? This has been like this for about 6 months now and I can go on a highway..

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My thoughts are a vacuum leak (a big one) or a faulty vacuum modulator at the transmission. No, the vacuum line to it doesn't have tranny fluid in it, but I replaced it, and I wonder if it's bad. Yes, I made sure to put the little metal pin/link back in it.

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