Ford Aerostar :: 1992 - Transmission Goes Out Of Gear When Accelerate To Downshift In OD


Sep 4, 2014

I searched a lot but did not find these symptoms on my 1992 Aerostar 3.0 2WD with A4LD transmission.

In overdrive, accelerate to down shift, and the transmission goes out of gear. Engine revs as if it was taken out of gear. Manually shift to Drive, and it works fine.

Overdrive works fine if at speed, and works to shift up, but if going slow enough to drop to lower gear, transmission goes out of gear. Manually in drive, works fine.

I may have other symptoms, but this was on the way home from work, and I just parked it. I checked fluid level, and it was fine, still in the cross-hatch area of the stick, light colored oil, no smell.

I will replace the modulator and replace the filter, and see what that will do. If the overdrive works at overdrive speed, I do not see how that could be an overdrive housing failure that I have seen in many posts. I am aware of keeping track of the pin for the modulator.

I also have read that band adjustment is not a good idea. If they are worn that bad, they should be replaced. I don't think it is a band or clutch problem. I think it is a shift control problem. We will start with the modulator and filter and take it from there.

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Like I said, if I use the gear selector to manually shift, it will go to all four gears just fine.

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The spark plugs and ignition wires were replaced last week. The car has 105k miles on it. I know the previous owner used regular unleaded, and the owners specifically states that 91 octane should be used and goes as far as to mention precautions that should be taken should regular unleaded. The car was filled up with 93 octane fuel earlier today.

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Well, replacing that regulator didn't work either. I don't know where to go from here. It totally cuts out at higher speeds when it's warmed up. Could it be the oxygen sensor? It can't be the plugs. I don't think it can be the sending unit in the tank even though I changed its pump. Is there another fuel filter somewhere? I'm moving to another town and I have to get the van there.

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Thinking I didn't set it right, I reinstalled the belt on the crank and tried again. Same result (belt rides up one groove, towards the fan). I perused the archives, and one comment was that someone simply trimmed one groove off the belt and everything was happy. The belt found it's "groove", and didn't act up anymore. Doesn't fix the underlying problem, but

1) is this a good fix
2) any clue what is going on?
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BTW, I am sure that I threaded the belt on correctly!

1992 Aerostar, 4.0L, AWD. AC+P/S....

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Let it cool for a bit, then limped over to the Lowe's parking lot. Conveniently, there's an Auto Zone there too! My wife picked me up, and I loaded the car with jack, stands, and tools, plus a quart of gear oil left over from when I changed a seat on the 95. Long story short, pulled the driver side axle, and the wheel bearing was completely disintegrated! Luckily, I was able to get my paycheck a day early, so I can pick up the new bearing in the morning, as well as 'rent' the bearing puller.

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