The steps generally involve:
1. Wheel Removal: Remove the wheel on the side of the axle you're removing.
2. Brake Caliper Removal: Remove the brake caliper and support it securely to prevent damage to the brake line. You may need to use a wire or bungee cord to keep it out of the way.
3. Rotor Removal (Possibly): Depending on how things are assembled, you *might* need to remove the rotor. This is usually held on by a few bolts.
4. Shock Absorber/Strut Removal (Likely): This is crucial. The shock absorber or strut (depending on your Aerostar's suspension) is likely connected to the axle assembly. You'll need to remove it from its mounting points. This typically involves removing bolts, and a spring compressor might be necessary to safely compress the spring before removing the strut. Never work on a compressed spring without the proper tools and safety precautions. Improper handling can lead to serious injury.
5. Ball Joint Separation: The lower ball joint connects the steering knuckle (which is part of the axle assembly) to the control arm. You'll need a ball joint separator tool to separate it safely. This tool helps prevent damage to the ball joint.
6. Tie Rod End Separation: The tie rod end connects the steering knuckle to the steering linkage. You'll need a tie rod end separator tool.
7. Axle Removal: With the ball joint, tie rod, shock/strut, and brake caliper out of the way, *then* you should be able to carefully maneuver the axle out. You may need to gently work it, possibly using a pry bar (carefully!) to dislodge it from any remaining points of contact.
Important Considerations:
* Repair Manual: Get a repair manual specific to your 1992 Ford Aerostar. This will provide diagrams and detailed instructions for safe removal and reassembly.
* Safety: Use jack stands to securely support the vehicle. Never work under a vehicle supported only by a jack. Wear safety glasses and gloves.
* Tools: You'll need a variety of tools including wrenches, sockets, a ball joint separator, a tie rod end separator, potentially a spring compressor, and possibly a pry bar.
* Component Condition: Inspect all components (ball joints, tie rod ends, etc.) during removal. If they show signs of wear or damage, replace them.
This is a complex job. If you are not comfortable working on car suspension, it is strongly recommended you take it to a qualified mechanic. Improperly removing or reinstalling the axle can lead to dangerous driving conditions and serious damage to your vehicle.
