Aerostar 4x4 build.

jovibuilt

New member
Longtime lurker here. I wanted to build a E150 with a ujoint kit but no more than I would use it I can not justify the money. I have tons of ranger parts. Been a RVB fan for years. So I have everything to swap a aerostar to 5 speed and 4wd. I am hoping you guys can give me pointers if I head the wrong direction. This will be a SLOW build probably take a year or so due to work and little free time. I am only looking at running 33" tires and using to do snow runs and camping/fishing spots. Only drw back is van has to be lifted enough for rear tires to clear sliding door at ride height.I want something I can jump in and run 75 mph on the interstate.
So parts acquired are.
15x10 aluminum wheels with 32x11.50 bfg at tires to be replaced with 33's after they wear out.
Brand new Lund visor for the van.
Plan on diy bumpers front and rear with 9500 lb winch in front and 5000 lb in rear. Brand TBD.
Factory clutch pedal set up with new factory clutch master cylinder (rockauto) need a clutch line TBD
Newly rebuilt mod 5 speed (93 ford explorer) with center force clutch.
BW 1350 transfer case (looking for a 1356 fixed yoke but maybe not needed as I am only wanting 33" tires)
1999 jeep xj HP dana 30 with 3,55 gears to match my stock rear end will regear after swap is done to 4.88 or 5.13.
Early model bronco 5.5 coils for front they were cheap to have a starting point.
I have a 91 explorer steering box tapped for Hydro assist. May need a gm box that mounts out side the frame due to bottom radiator hose,TBD.
Plan to ditch rear coils and and swap in rear leaf spring like toyota guys do to 4runners. Have several different sets of lift springs for rear RVB's. I plan on using the rear factory link mounts on the frame. For the rear springs front mount and make the rear shackle mounts.
Plan for the front is Ruffstuff DIY radius arms.
.
 

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jovibuilt

New member
That was a test on posting pictures. I have two 95 model Aerostar vans. One for parts and one that runs and drives. But it has crappy door panels,paint and needs a ac compressor. I have found a NICE red 96 model for sale local for $1999.00 may buy it if it has no rust when I go look at it. All three have 4.0 motors. And does anyone know this brand of wheels? I need new center caps.
 

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jovibuilt

New member
I have a few pictures of a 4x4 swapped Aerostar from another board I am on. It has a full width hp dana 44 front and a rear full width 8.8 with 35's. I think now it has a v8 swap and a 435 4speed with a 205 case. The guy wheels it hard.
 

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Oldcarnut

Adventurer
Back in the day the Big Foot team had an Aerostar. Supercharged V6 n way cool. If it was an extended body it would have been my dream.
Good luck on the build and I anxiously await updates.
 

wanderer-rrorc

Explorer
Dunno much about them...know everything about rangers thou...
841d799ec785a300429a2bb7f45ab49a.jpg


Sent from my moto z4 using Tapatalk
 

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