However, if you're determined to do it yourself, here's a general outline. Remember this is a general guide, and specific procedures may vary slightly depending on your exact Aerostar's configuration. Always consult a repair manual specific to your year and model for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools and Materials You'll Need:
* Repair Manual: Absolutely essential.
* Jack and Jack Stands: Properly support the vehicle. Safety first!
* Wheel Chocks: Critical for safety.
* Socket Set and Wrenches: Various sizes.
* Torque Wrench: To tighten bolts to the correct specifications.
* Penetrating Oil (PB Blaster, etc.): Helps loosen rusted bolts.
* Pry Bar or Gear Puller: May be needed to remove the axle flange.
* Hammer and Punch (brass is best): For carefully tapping parts.
* New Axle Seal: Get the correct part number from a parts store, providing your Aerostar's VIN is best.
* New Axle Nut: Often recommended to replace.
* Grease: For the new seal and axle.
* Clean rags or shop towels: Keep things clean.
* Gloves: Protect your hands.
* Safety Glasses: Protect your eyes.
General Steps (Consult your repair manual for precise details):
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks. Raise the vehicle securely using a jack and support it with jack stands.
2. Remove the Wheel and Brake Drum/Rotor: Remove the wheel and then the brake drum or rotor. You may need to use a drum puller if the drum is stuck.
3. Remove the Axle Flange Nut: This nut is usually very tight. Use penetrating oil and a breaker bar or impact wrench if necessary. Mark the nut's position relative to the axle flange before removing it.
4. Remove the Axle Flange: This can be tricky. You may need a pry bar or gear puller to carefully remove the flange. Be cautious not to damage the axle shaft.
5. Remove the Old Seal: Carefully remove the old seal using a seal puller or a flathead screwdriver (carefully, to avoid damaging the axle housing).
6. Clean the Axle Housing: Thoroughly clean the axle housing where the new seal will go. Remove any old grease, dirt, or debris.
7. Install the New Seal: Carefully install the new seal, making sure it's seated correctly. Usually, tapping the seal in evenly with a socket that's slightly smaller than the seal's outer diameter is recommended. Do not hammer directly on the seal.
8. Reassemble: Reinstall the axle flange, making sure it's properly seated. Tighten the axle nut to the specifications in your repair manual using a torque wrench. This is crucial to prevent damage.
9. Reinstall Brake Drum/Rotor and Wheel: Reinstall the brake drum or rotor and the wheel.
10. Lower the Vehicle: Carefully lower the vehicle.
11. Check for Leaks: After driving a short distance, carefully inspect the area for any leaks.
Important Considerations:
* Axle Bearings: Inspect the axle bearings while you have the axle flange removed. If they're damaged or worn, they should be replaced.
* Fluid Level: Check and replenish the rear differential fluid after the repair. Use the correct type and amount specified in your repair manual.
* Torque Specifications: Strictly adhere to the torque specifications in your repair manual for all bolts and nuts. Over-tightening can cause damage.
This is a complex repair. If you're not comfortable with any of these steps, it's strongly recommended to have a professional mechanic perform the work. Incorrectly replacing the seal can lead to serious damage to your vehicle's rear axle.
