1. Assess the Damage:
* Remove the Interior Panel: This will give you access to the sliding door mechanism. You'll likely need to remove screws and possibly some plastic clips. Search online for a 1993 Ford Aerostar sliding door panel removal guide – plenty of videos and instructions are available.
* Inspect the Rod: Look closely at the rod itself for bending, significant wear, or damage beyond the slippage. If it's severely bent or worn down, it needs replacement.
* Examine the Latch Lever: Check the latch lever for any cracks, breaks, or excessive wear. If it's damaged, it'll also need replacing.
* Check the Roller(s): The rollers at the top and bottom of the door that guide it along the track are crucial. Inspect them for wear, breakage, or misalignment.
2. Repair or Replace:
* If the rod is only slightly worn: You might be able to add a small sleeve or bushing (a short metal or plastic tube) around the worn part of the rod to take up the slack and prevent it from slipping through the latch. This is a temporary solution at best.
* If the rod is bent or severely worn: Replacement is necessary. You should be able to find replacement parts online (eBay, auto parts stores) or at a salvage yard.
* If the latch lever is damaged: It also needs replacement.
* If the rollers are worn or damaged: Replace them. These are relatively inexpensive parts.
* Lubrication: Once you've addressed any damaged parts, lubricate all moving parts with a suitable lubricant, such as silicone spray or white lithium grease. Avoid using WD-40 as it's a solvent and will eventually evaporate.
3. Reassembly:
* Carefully reassemble the door mechanism, ensuring everything aligns correctly.
* Reinstall the interior panel.
Important Considerations:
* Safety: Before you start working on the door, disconnect the battery's negative terminal to prevent accidental electrical shocks.
* Parts: Finding replacement parts for a 1993 vehicle might require some searching. Auto parts stores may need to order them. Salvage yards are another good option.
* Professional Help: If you're uncomfortable working on the door mechanism yourself, take it to a mechanic or auto body shop. The cost of repair might be less than the cost of damaging something further while attempting a DIY repair.
Using a vice grip and hammer is a dangerous and likely ineffective long-term solution. It risks further damaging the mechanism and potentially injuring yourself. Take your time, be thorough in your inspection, and obtain the proper replacement parts for a lasting fix.
