1. Identify the Problem:
* Difficult Shifting: This could be due to worn bushings, bent linkage, a loose cable (if cable-operated), or adjustment issues.
* Shifting into the Wrong Gear: This often points to a bent or misaligned linkage component.
* Shifter Feels Loose or Floppy: This suggests worn bushings or loose mounting points.
* No Shift at All: This is the most serious and could involve a broken cable, severely damaged linkage, or even a transmission issue (last resort).
2. Gather Tools and Supplies:
* Jack and Jack Stands: Essential for safe working conditions.
* Wheel Chocks: For added safety.
* Socket Set and Wrenches: Various sizes will be needed.
* Screwdrivers: Phillips and flathead.
* Pliers: Needle-nose and regular.
* Penetrating Oil (like PB Blaster): Helps loosen rusted or seized parts.
* Replacement Parts: This might include bushings, linkage components, cable (if applicable), and possibly even a new shifter handle. You might need to visit a parts store or search online using your Aerostar's VIN number for the correct parts.
* Workshop Manual: A factory service manual is invaluable for detailed diagrams and procedures. You can often find these online (eBay, etc.).
3. Accessing the Linkage:
The Aerostar's shifter linkage is located under the vehicle, near the transmission. You'll need to get under the car safely using your jack and jack stands. The exact location and accessibility will depend on whether it's a cable-operated or rod-operated system.
4. Common Problems and Solutions:
* Worn Bushings: These are small rubber or plastic components that allow for smooth linkage movement. They wear out over time causing sloppy shifting. Replace these with new bushings. You may need to carefully remove the old ones (sometimes they're pressed in) and install the new ones.
* Bent Linkage Rods: Inspect the rods carefully for bends or kinks. If bent, they'll need to be straightened or replaced. Straightening is tricky and may weaken the rod. Replacement is usually preferred.
* Loose Linkage: Check all mounting points for loose bolts or nuts. Tighten anything loose.
* Loose or Worn Shifter Cable (if applicable): If your Aerostar uses a cable system, check for fraying, stretching, or loose attachments at the transmission and shifter. Replacement might be necessary.
* Adjustment: Many shifter linkages have adjustment points. Consult your workshop manual to see how to properly adjust the linkage for optimal shifting. This often involves tightening or loosening nuts on the linkage rods or cable.
5. Reassembly:
Once you've repaired or replaced the necessary components, reassemble everything in reverse order of disassembly. Make sure all bolts and nuts are tightened securely.
6. Test:
After reassembly, lower the vehicle and test the shifting. Make sure all gears engage smoothly and correctly.
Important Considerations:
* Safety First: Always use jack stands and chocks when working under a vehicle. Never rely solely on a jack.
* Proper Lubrication: Lubricate linkage components with a suitable lubricant after repairs.
* Professional Help: If you're not comfortable working on your vehicle, it's best to take it to a qualified mechanic. Improper repairs can lead to further damage.
This is a general guide. The specific repair procedure will depend on the exact nature of the problem. Using a repair manual specific to your 1993 Ford Aerostar is highly recommended. Remember safety first!
