Well, here are a few pictures of my Aerostar. Lets start out with my exhaust system.
The factory converter is still in place and the section of pipe is 2.25" Ford used a 2" flex pipe and muffler on both the 3.0L and 4.0L. This is smaller than the size pipe they use on the 4.0L converter system. Ford did this for budget reasons, and also so that both models would share more parts. The 2" muffler is ok for the 3.0L, but does limit the 4.0L.
I had a 2.25" flex pipe installed, and ran 2.25" pipe back to the muffler. This eliminated a restriction in the factory system, plus the 2.25" flex pipe is less prone to failure. For the muffler I used our FullBlown brand 50 series muffler. This is similar in to the Flowmaster 50 series. I used a 2.50" tailpipe for two reasons. One, is that unless you use a mandrel bender, the pipe gets crushed slightly, reducing flow in the bend. And two, the larger pipe projects more sound outward. the result is that the volume level outside is pretty good, without causing resonation and droning inside the van. I ended it all in one of our WickedFlow stainless steel tips.
Here are the pictures.
I am also running some very nice Cooper LT tires, which are awesome in the snow, but more importantly they also have an excellent tread life and can handle a lot of weight. I have installed some very attractive looking hubcaps from a vintage Ford Fairlane. (the tires shown here are not the Coopers, but the tires seen above are)
I have installed some other extras such as the clear LED taillights (not legal in all states) and a new grill which will give me enough room to install an electric pusher fan in front of the condenser. I have a few other mods which are not visual modifications, such as a headlight relay harness, which prevents the headlight switch and high-beam switches from burning out, and also makes the headlights brighter. I have an AFE ProDryS air filter which is washable but does not require oiling and does not let small dust particles through. It is a direct replacement type filter that just goes inside the stock airbox. I like that all I have to do is rinse it with water, tap it dry, and then put it back in. I have an overbuilt A4LD transmission with the heavy duty torque converter and a modified valve body with the pressure boost kit (also known as a shift kit). I have a B&M plate cooler to keep the tranny cool. I have removed all the back seats and replaced the carpet with a liner called BedRug. It looks like carpet, but it is a type of bed liner material.
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'94 Aerostar 4.0L XLT AWD 192,000
overbuilt A4LD trans with shift kit
Custom catback exhaust with Fullblown 50 series muffler
