Here's a general outline of the process. Specific steps may vary slightly depending on the exact transmission type (e.g., A4LD, etc.) in your Aerostar. Always consult a repair manual specific to your vehicle's year and transmission type for detailed instructions and torque specifications.
Tools You'll Likely Need:
* Transmission Jack: Absolutely essential for supporting the transmission.
* Torque Wrench: Crucial for tightening bolts to the correct specifications.
* Socket Set: Various sizes, both metric and standard.
* Wrenches: Combination and open-end wrenches in various sizes.
* Pry Bar: May be needed to help remove the old seal.
* Seal Installer: To properly install the new seal without damaging it.
* Transmission Fluid: The correct type and quantity for your transmission.
* Drain Pan: To catch old transmission fluid.
* Shop Rags or Paper Towels: For cleanup.
* Safety Glasses and Gloves: Protect yourself.
* Repair Manual: A MUST for specific instructions and torque specs.
General Steps (This is NOT a comprehensive guide, consult your repair manual):
1. Safety First: Disconnect the negative battery terminal.
2. Vehicle Preparation: Raise and securely support the vehicle on jack stands. *Never work under a vehicle supported only by a jack.*
3. Fluid Drain: Drain the transmission fluid completely into a drain pan.
4. Transmission Removal (Possibly): Depending on access to the front seal, you may need to partially or fully remove the transmission. This typically involves disconnecting the driveshaft, shift linkage, cooling lines, and torque converter. This is the most challenging part of the job and requires careful attention to detail.
5. Seal Removal: Once access is available, carefully remove the old front seal. A pry bar might be helpful, but avoid damaging the transmission case.
6. Clean the Housing: Thoroughly clean the transmission case where the new seal will sit. Any debris can prevent a proper seal.
7. New Seal Installation: Use a seal installer tool to carefully install the new seal. Avoid damaging the new seal's lip.
8. Reassembly: Carefully reassemble everything in the reverse order of removal. Pay close attention to torque specifications for all bolts.
9. Fluid Refill: Refill the transmission with the correct type and quantity of transmission fluid.
10. Check Fluid Level: Check the transmission fluid level using the dipstick (if equipped) and add more fluid if necessary.
11. Test Drive: After reassembly, carefully test drive the vehicle, paying close attention to the transmission's operation. Check for leaks.
Important Considerations:
* Transmission Type: The exact procedure will vary based on the specific automatic transmission in your Aerostar. Knowing the transmission type (e.g., A4LD) is crucial for finding the correct repair manual and parts.
* Torque Specifications: Using the correct torque specifications is critical to prevent damage. Always consult your repair manual.
* Seal Compatibility: Ensure you purchase the correct replacement seal for your transmission.
This is a simplified overview. It's strongly advised to obtain a reliable repair manual specific to your 1993 Ford Aerostar and follow its instructions precisely. Attempting this repair without proper knowledge and tools could lead to significant damage and costly repairs. If you're not comfortable with this level of automotive repair, seek professional help.
