I will be upgrading this site as I remember something I forgot. Will also add pictures as I Rebuild the Engine. So Check Back from Time to Time
How I Pulled the Engine Through the Front of My Aerostar
The first thing I did was to put the front wheels of the van up on ramps. Then I jacked up the rear end and put a jack stand under each end of the back axle. Unhooked the battery cable from the battery. Drained the Radiator. Unbolted Transmission fill tube and removed through the top.
WARNING:::::START WITH A ROLL OF MASKING TAPE AND A FELT MARKER. WRAP AND MARK EACH VACUUM LINE AND CABLE AS YOU TAKE THEM LOOSE. PUT A PIECE A TAPE WHERE THEY CAME LOOSE FROM WITH THE SAME NUMBER, LETTER, OR SYMBOL.
Now under the Car.......
Drained the Oil and removed the sending unit that is screwed into the side of the Oil Pan.
Removed the drive line. Unhooked all the cables and wires from the transmission.
Unhooked wire from starter and remove starter. Opened little plate on Transmission and removed the 4 nuts on the torque converter. Unscrewed cooler lines from transmission. Removed bolts holding Transmission to engine. Put floor jack under transmission with a 12" long 2x6 between the jack and transmission. Removed the 2 nuts holding the transmission mount to the cross-member, then took out the 2 bolts holding the cross-member to the body. Pulled the transmission back and lowered it to the ground with the jack.
Put the Jack under the back of the engine to keep it from leaning back far enough to break the motor mounts.
Unbolted and removed the Catalytic converter.
On the rail removed the 2 gas lines going to the (Fuel Filter) Gold Can looking thing.
Inside the Cab.........
Put Shifter into Low. Removed cover. Unplugged Large Round Plug and Plug on Distributor. Made sure that Vacuum lines coming off of the Vacuum Block were loose on their other ends.
Up on Top........
Unscrewed the clutch Fan and removed. Removed the fan shroud. Undid the Hoses on the radiator and transmission cooler lines. Removed Radiator. Removed air cleaner. Removed front grill. Removed Bumper cover. Pulled back Passenger side turn signal/parking light and unplugged wire from light. Unplugged wire from headlight. Unplugged plugs from A/C & condenser, the fan, the one on the fire wall to the heater, the alternator,
Removed the hood. Removed the screws from the hood latch bar and a couple behind it. Removed bar and unhooked latch release cable.(C2 from C1)
Pulled electrical harness over to the right side.
Removed belts from engine and pulleys. Removed alternator. Removed power steering pump and unscrewed line from the steering gear.(Marked with a White Box on picture below)
Laid pump under car. Also tied up Transmission radiator under car.
Pulled A/C radiator to the side and removed 4 bolts on the A/C pump and tied it and A/C radiator back out of the way.
Unhooked accelerator cable from engine and move out of the way.
Unhooked Vacuum line from Power Brake Assist. Careful not to break off the plastic arm unhooking the line.
Hooked the Cherry picker to the engine.
(I didn't BUT... Remove the Intake Manifold before you take the Engine out. It will make it a lot Easier & you'll be able to lift the engine higher)
Doubled checked that I had everything loose. Unhooked the Motor Mounts and pulled the engine.
Afterthoughts........
If you noticed, I left the top Intake Manifold on when I pulled the Engine. I would Remove it the next time I pulled another Aerostar Engine. With it on , it doesn't give much lifting room.
I will leave it off when I put the engine back in. Also leaving the Exhaust manifolds on seems to cause NO problems pulling the Engine Out. Makes it easier to get them off with the Engine out. Same thing with the Heads.
To Dismantling/Rebuilding the Engine Page........
Ordered a Master Rebuild Kit from Flat Lander Racing. The Kit cost $399.00 plus shipping =$433.81.
Kit comes with....Pistons, Rings, Camshaft, Cam Bearings, Rod Bearings, Main Bearings,Lifters, Oil Pump, Timing Set, Freeze Plugs, Pre Lube, Complete Gasket Set.
Web Site is www.flatlanderracing.com
Parts were ordered on 11/25 Arrived 12/4. Shipped from Philadelphia, PA. to Northern California .............Pretty Fast at the Holiday Time.
List of Parts Received
Melling Engine Parts
Oil Pump M129 ...... Timing Set 3-374S ...... CamShaft Sub-50
Pioneer inc. Automotive Products
Freeze Plug Set Pe-252-R
Federal Mogul
Rod Bearings 1220RA ...... Main Bearings 7011 MA
Dura-Bond
Camshaft Bearings F-48
Hastings
Piston Rings 5762
Sealed Power
Pistons H497P STD.
Victor Reinz Gaskets
Gasket Set ...... 95-3295VR / KS2352
Lifters Came in a Plain Box
hits.