Safety First:
* Disconnect the negative battery terminal (-) before starting any work. This prevents accidental shorts and shocks.
* Wear safety glasses to protect your eyes from flying debris.
* Use jack stands if you need to lift the vehicle. Never work under a vehicle supported only by a jack.
* Have the correct tools before you begin.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Various size wrenches (metric)
* Pry bar (possibly)
* Wire brush (to clean battery terminals and starter connections)
* Torque wrench
* New starter motor (make sure it's the correct one for your engine)
* Penetrating oil (like PB Blaster)
Removal Procedure:
1. Locate the Starter: The starter is usually on the passenger side of the engine, towards the bottom. It'll be a relatively large, cylindrical component with thick cables attached.
2. Prepare the Area: Remove any components that might obstruct access to the starter, such as the air cleaner housing or heat shields (if necessary). You might need to loosen or remove some parts.
3. Disconnect the Battery Cables: Use a wrench to disconnect the large cables (positive and negative) attached to the starter. Note which cable goes where. Take pictures if helpful.
4. Remove Starter Bolts: The starter is held in place by typically two or three bolts. These can be difficult to access. Use penetrating oil to loosen them if they're stubborn. You'll likely need a socket wrench with extensions to reach them.
5. Remove the Starter: Once the bolts are removed, the starter may be held in place by its mounting bracket. It may require some wiggling and possibly a pry bar to get it loose. Be careful not to damage any surrounding components.
Installation Procedure:
1. Clean the Mounting Surface: Clean the starter mounting surface on the engine block and the starter itself with a wire brush.
2. Install the Starter: Carefully align the new starter with its mounting holes.
3. Tighten the Bolts: Secure the starter with its bolts, tightening them to the manufacturer's specified torque (found in your repair manual). Don't overtighten.
4. Reconnect the Battery Cables: Reconnect the positive (+) and negative (-) battery cables to the starter, ensuring they are securely fastened.
5. Reconnect Everything Else: Reinstall any components you removed to access the starter (air cleaner housing, etc.).
6. Test the Starter: Reconnect the negative battery cable. Try starting the engine.
Important Notes:
* Grounding: Poor grounding can cause starting problems. Make sure the engine block and battery are properly grounded.
* Solenoid: The starter solenoid is the small electrical component on top of the starter. If the starter motor works but doesn't engage, the solenoid might be faulty and require replacement.
* Professional Help: If you're uncomfortable with any of these steps, take your Aerostar to a qualified mechanic. Working on a vehicle requires mechanical aptitude and the right tools. Improper installation can lead to damage or injury.
This is a general guideline; the exact procedure may vary slightly depending on your specific Aerostar model and engine type. Refer to a repair manual for your vehicle's year, make, and model for detailed instructions and diagrams. This will make the job much easier and safer.
