Posted: Mon Mar 07, 2005 9:59 am
youcan use the 2.9L monts, they bolt in.
if you use the 2.9L flywheel then you will need to use the starter from an automatic 4.0L which if you have a complete automatic aerostar then the starter will work for what you will be using. I will recomend that you use the 4.0L flywheel for better transfer of torque but I ran the 2.9L because of the tranny not being rated to handle the motor. clutches are cheaper then tranny's.
the van manifolds will work but you will need to notch the passengerside motor mount to clear.....you will see what I am talking about when you go to assemble. you will have to make your own y pipe for the exhaust.
the other thing you need to be aware of is the oil filter pickup......if you use the one from the aerostar you will have to clearence the bell housing to fit the FL1A oil filter, or switch to a FL400S (both motor craft numbers, fram is PH8A or PH3600) I just used the 400S and called it good. but it is personal preference. if you decide to use the other pickup then you might need to run the other manifolds because of clearence issues. I didn't try this but you might be able to use the 2.9L pickup because they are from the same block family they might interchange.
the exhaust maifolds from the 2.9L will physicly bolt on but if you look at the 2 manifols the port diameter is way different. if you grind to port match you will crack the manifold from the heat transfer of the metal. at this point you have options to run the factory junk from the aerostar, run exploder maifolds, or get headers.
if you use the 2.9L flywheel then you will need to use the starter from an automatic 4.0L which if you have a complete automatic aerostar then the starter will work for what you will be using. I will recomend that you use the 4.0L flywheel for better transfer of torque but I ran the 2.9L because of the tranny not being rated to handle the motor. clutches are cheaper then tranny's.
the van manifolds will work but you will need to notch the passengerside motor mount to clear.....you will see what I am talking about when you go to assemble. you will have to make your own y pipe for the exhaust.
the other thing you need to be aware of is the oil filter pickup......if you use the one from the aerostar you will have to clearence the bell housing to fit the FL1A oil filter, or switch to a FL400S (both motor craft numbers, fram is PH8A or PH3600) I just used the 400S and called it good. but it is personal preference. if you decide to use the other pickup then you might need to run the other manifolds because of clearence issues. I didn't try this but you might be able to use the 2.9L pickup because they are from the same block family they might interchange.
the exhaust maifolds from the 2.9L will physicly bolt on but if you look at the 2 manifols the port diameter is way different. if you grind to port match you will crack the manifold from the heat transfer of the metal. at this point you have options to run the factory junk from the aerostar, run exploder maifolds, or get headers.
