Aerostar Door Woes

On Mon, 2 Jul 2012 10:44:02 -0700 (PDT), uncle K


 The side door may need the whole roller assembly - Is the track still
smooth, or all rusted? Here in Ontario they rusted some.
The rear hatch pivot MAY be available separately from Ford - I know I
bought an aftermarket stud from a trailer joint for mine a decade or
so ago.

On Jul 2, 12:00=A0pm, cl...@snyder.on.ca wrote:


The track is clean.  Amazingly, in the PNW, no rust.  You can't see in
there easily, but since it rolled fine before, but suddenly began to
deteriorate, fast, I kind of assume a roller, or rollers gave up the
ghost.  Ford doesn't stock much for a vehicle this old, but can get
some parts... for an outrageous price.  I found replacement rollers
for cheap on the web, if that's something which can be done without a
machine shop.

Same story with the rear door lift support strut.  They worked fine,
then the right side suddenly exploded at the ball and socket
connection.  When it broke, the ball pulled out of the socket.  Hope
that doesn't cause a complication.  That broken piece ought to be
worth about a dollar, but it appears I'll have to buy a new strut, or
maybe a pair, just to keep the pressure/compression equal on both.

On Mon, 2 Jul 2012 14:32:43 -0700 (PDT), uncle K


  Like I said, on my '91 I bought a ball pivot from a camper supply
place - used on the struts on a pickup cap - cost me something like 4
bucks Canadian. I cannot remember the details on the door rollers - I
had to replace my door track (just below the windows) and repaired the
lower roller bracket. IIRC it cracked and I had it welded - but I
cannot remember for sure. I sold the van something like 10 or 12 years
ago,

On Jul 2, 4:00=A0pm, cl...@snyder.on.ca wrote:


The rear gate problem turned out to be a chain reaction.   Fully
extended, the strut froze up, causing the ball/stud to snap off under
the full weight of the door.  It occurred to me, if the reverse
happened, and the strut suddenly lost compression while it was up, it
would amount to a large rat trap.  Yikes.  The local Ford dealer has
the stud, and replacement lift struts are on their way.  You know how
this works.  If you only replace the broken side, the other side will
probably go sooner, rather than later, so I ordered the pair.  Now, to
drill out the broken end of the bolt.  A body man is going to help
solve the side door malfunction.

But first, we shall celebrate our independence.  Thanks for cutting us
loose, eh.

Unk

If that's the first time the rear door strut failed, you're doing good.  =
Mine's a 97 and original struts are still holding up.   If mine ever =
fail, I'll replace with original equipment even if the are 5 times the =
price.  Also have a small hatchback car and I have replaced the struts =
with El Cheapo aftermarket crap 4 times in the 13 years I've had it.