Ford Aerostar :: Sliding Door Eventually Drop Down And Back A Few Millimeters - Alignment?


Oct 6, 2013

One of my Aerostar pet peeves is to do with the sliding door alignment, or should I say slight misalignment.

Some of the alignment problems can be attributed to worn out nylon roller bearings. Make sure the roller guide ways are clean of any foreign debris. When you car wash your Aero, make sure to also clean the interior roller guide way (open the sliding door and thoroughly clean around the area where the bottom sliding door wheel travels).

After 20 years of usage, the sliding door will eventually drop down and back a few millimeters. Some of the symptoms associated with this will be a sporadic loss of electrical contact with those that are outfitted with electrical door locks. Also, the sliding door may also require some manual assistance at back edge to open the door. It can become somewhat frustrating, and perhaps a little embarrassing when parked beside a newer vehicle outfitted with automatic door opening/closing mechanisms.

I am not sure if the elevation of the sliding door can be adjusted at the rear or in the middle, but I do know that the horizontal position of the sliding door can be adjusted to a certain degree. The vertical position can be only adjusted by a very tiny amount.

1) Remove all of screws on the sliding door interior panel, and as well as the torx screw on the open/close barbaric door handle.
2) The bottom panel, other than the screws, has 2 plastic/nylon semi-resuble flat headed holder fittings.
3) Remove the two interior rubber grommets at the rear edge of the door. This will reveal 3 adjustment bolts.
4) Loosen the bolts, then push the door a bit forward while holding the middle hinge. Don't push too much! Just a little.
5) Re-tighten the middle handle bolts, and subsequently re-adjust the striker bolt. This is a PITA to align properly.

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