1. Assess the Damage:
* How much is broken off? If only a small portion is broken inside, you might be lucky. If a significant piece is embedded and inaccessible, it'll be more complex.
* Location of the break: Is the break near the body or the hatch? A break near the hatch is easier to manage.
* Accessibility: Can you see or reach any part of the broken support with tools?
2. Attempt Removal (If Possible):
* Needle-nose pliers/gripping tools: If you can get a grip on the broken end, try carefully using needle-nose pliers, locking pliers (like Vise-Grips), or even a small grabber tool to pull it out. Work slowly and gently to avoid further damage to the body.
* Small screw extractors: If there's a threaded portion sticking out, carefully drill a pilot hole into the broken piece and use a screw extractor to remove it. Be extremely cautious not to damage the surrounding body metal.
* Drill and tap (last resort): As a last resort, you might carefully drill out the broken piece. This is risky and could damage the body. If successful, you might be able to tap the hole and use a bolt to secure the new lift support. This requires precise work and potentially a helicoil to repair the damaged threads.
3. Installing the New Lift Support:
Once the broken piece is removed (or if it's mostly intact and just needs replacing):
* Prepare the area: Clean the mounting area thoroughly of any rust, debris, or broken pieces.
* Install the new lift support: Carefully align the new lift support with the mounting points on the hatch and body. You may need a helper to hold the hatch in place while you secure the new support. Sometimes these use a bolt and sometimes they use a pin or other fitting.
* Test the lift support: Once installed, carefully test the new lift support to ensure it operates smoothly and the hatch opens and closes without binding.
4. If Removal is Impossible:
If you can't remove the broken piece, your options become limited:
* Leave it: If the remaining broken piece doesn't interfere with the new support's functionality, you might be able to install the new support alongside the broken piece. This isn't ideal, but it could work.
* Professional help: An experienced body shop or mechanic may have specialized tools or techniques to remove the broken piece, potentially involving drilling and patching the bodywork. This is the most costly option but often the most reliable.
Important Considerations:
* Safety: Always wear safety glasses when working with metal and tools.
* Patience: This repair can be frustrating. Take your time and avoid rushing.
* Rust prevention: Apply rust inhibitor to any exposed metal after the repair to prevent future issues.
* Correct lift support: Ensure you purchase the correct lift support for your specific Ford Aerostar year and model. Auto parts stores can help you identify the right one.
If you're not comfortable performing this repair yourself due to the complexity and potential for further damage, it's best to seek professional help from a qualified mechanic or body shop. The cost of professional repair might be less than the cost of further damage caused by attempting a DIY fix.
