Tools You'll Need:
* Wrench(es): You'll likely need a few different sizes, depending on the alternator and tensioner bolt sizes. Check your vehicle first.
* Socket wrench and sockets: Makes the job easier.
* Ratchet: To use with your sockets.
* Jack and jack stands (highly recommended): Provides better access and safety. Never work under a vehicle supported only by a jack.
* Gloves: To protect your hands.
* New alternator belt: Make sure you get the correct size and type for your Aerostar. Check your owner's manual or a parts store.
* Possibly a belt tensioner tool (depending on your year): Some Aerostars have automatic tensioners, others may require a special tool to release tension. Check your vehicle.
Procedure:
1. Safety First: Disconnect the negative battery cable. This prevents accidental shorts and protects you from electrical shock.
2. Jack Up and Secure: Safely jack up the front of your Aerostar and secure it on jack stands.
3. Locate the Alternator and Belt: Identify the alternator and the belt that drives it. The belt usually runs around the crankshaft pulley, the alternator pulley, and potentially other pulleys (like the power steering pump).
4. Release Belt Tension: This is the trickiest part and varies the most by year.
* Automatic Tensioner: Many newer vehicles have an automatic tensioner. There will likely be a bolt or other mechanism to loosen the tensioner, allowing you to slip the belt off. Consult your repair manual for precise instructions.
* Manual Tensioner: Older Aerostars might have a manual tensioner. This usually involves using a wrench to loosen a bolt on the tensioner, allowing you to release the tension on the belt and remove it. Sometimes this involves leveraging a wrench against a part of the tensioner to create enough slack. Be careful not to over-tighten once you're finished.
5. Remove the Old Belt: Once the tension is released, carefully work the belt off the pulleys.
6. Install the New Belt: Route the new belt onto the pulleys in the same path as the old belt. Make sure it sits correctly in all the grooves.
7. Restore Belt Tension: Tighten the tensioner (if manual) or allow the automatic tensioner to return to its normal position.
8. Check Belt Tension: After tightening, check the belt tension. It should not be too loose or too tight. A slight deflection (give) when pressed should be present. Again, consult your repair manual for specifications.
9. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
10. Reconnect the Battery: Reconnect the negative battery cable.
11. Test: Start the engine and check for any squealing or unusual noises from the belt. If there are problems, double-check the belt routing and tension.
Important Considerations:
* Year and Model: The specific procedure may vary slightly depending on the year and model of your Ford Aerostar. Always consult a repair manual specific to your vehicle.
* Difficult Access: Working in the engine bay can be tight. Take your time and be patient.
* Proper Tension: Incorrect belt tension can lead to premature wear or belt failure.
* Professional Help: If you're not comfortable performing this repair yourself, take your Aerostar to a qualified mechanic.
This guide provides a general overview. Failure to follow proper procedures could result in injury or damage to your vehicle. Always prioritize safety and consult your vehicle's repair manual for detailed instructions.
