Ford Aerostar

Carousel: the garageable van

At Ford, development of a minivan began in the early 1970s. As the company was preparing the third-generation Ford Econoline for a 1975 introduction, Ford product planners began design work on a companion model based on the same chassis. In an effort to develop the concept of a "garageable van", Ford sought to create a van shorter in height and length, easily able to fit through the average-height American garage door opening.

Dubbed Ford Carousel, the "garageable van" shared its chassis with the standard-wheelbase Econoline/Club Wagon (124 inches). To make the Carousel a "garageable van", the roofline was lowered approximately 12 inches, with a redesigned front fascia and A-pillars. Similar to the 1955-1957 Chevrolet Nomad, the Ford Carousel had a forward-sloping B-pillar with wraparound side windows. In a key indication of being marketed as a family vehicle, the Carousel wore a rear tailgate with a drop-down rear window with simulated exterior woodgrain trim. Inside, it was fitted with two rear bench seats with interior trim similar to the Ford Country Squire and Mercury Colony Park.

While the Ford Carousel received a positive response by many Ford executives for a potential 1976 introduction, it ultimately would not reach production. While financial constraints forced the company to divert funds towards critical projects (such as the Fox platform and Panther platform), the 1973 energy crisis played a major role as well (the prototype was fitted with a 460 V8, shared with full-size Ford vehicles and one-ton Ford trucks).

In 1978, Lee Iaccoca and Hal Sperlich both departed Ford and were hired by Chrysler, leading to the development of the Chrysler minivans. While sharing the "garageable van" concept of the Ford Carousel, the 1984 Dodge Caravan and Plymouth Voyager would become far different vehicles in terms of layout and engineering.

Aerostar: all-new design

During the early 1980s, as the development of the Chrysler minivans became known in the American automotive industry, Ford commenced development of its own vehicle in response. The energy crises of the late 1970s had made fuel economy a high priority of vehicle design; as such, downsizing the Econoline/Club Wagon to a smaller height and length (the concept of the Ford Carousel) was no longer a competitive option for Ford.

While using the 6-foot height of the Carousel as a starting point in concept, the new Ford "garageable van" was a completely clean-sheet design. In a major shift, to help reduce weight, in place of using components from the full-size truck and van line, the new van adopted powertrain commonality with Ford Ranger compact pickup truck. In what would be a major break from the Chrysler and GM minivans, Ford gave its minivan a distinct chassis, with model-specific front and rear suspension.^[2] To further improve fuel economy, Ford added a number of lightweight materials for the body, using plastic bumpers, fuel tanks, liftgate doors, and hoods; aluminum was used for the driveshaft, axles, and wheels.^[2]

In 1984, the Ford Aerostar name was first used as Ford unveiled a concept vehicle previewing the final production minivan.^[3]

Chassis

1987 Ford Aerostar XLT

As with its Chrysler and General Motors minivan counterparts, the chassis of the Ford Aerostar derived a number of suspension and powertrain components from existing vehicles to lower development costs. Although it would become the first Ford truck to make use of a unibody chassis, the Aerostar shared most of its components with the Ford Ranger/Bronco II light trucks. To reinforce the chassis for towing and overall rigidity, the dedicated platform (codenamed VN1, the first alphanumeric designation for a Ford platform) was designed with full-length integrated frame rails. The addition provided the Aerostar with the same 5,000 pounds (2,300 kg) tow rating as the Chevrolet Astro/GMC Safari, and 2½ times the capacity of the Chrysler minivans.^[3][4]

The front suspension consisted of unequal length A-arms through its entire production; for 1990, the lower A-arm was revised to accommodate the addition of all-wheel drive as an option. The Aerostar differed from all other Ford light trucks in its rear suspension configuration as well. To save space, the live rear axle was fitted with a three-link coil-sprung rear suspension (similar to the Panther-platform cars of the time)^[2]. During its production run, the Ford Aerostar was the only North American-market minivan sold with four-wheel coil-spring suspension (the planned launch of the Renault Espace by AMC was stillborn).

While the planned four-cylinder diesel engine from the 1984 concept vehicle was dropped in the prototype phase,^[3] the Aerostar was launched with two engines from the Ranger/Bronco II: a standard 2.3 L four-cylinder (shared with the Mustang) and a carburetor equipped 2.8 L Cologne V6 (from Ford of Europe) for the first few months of production. Shortly after the introduction, the 2.8L V6 was replaced with the newly introduced electronic multi-port fuel injected 3.0 L Vulcan V6 from the Ford Taurus/Mercury Sable,^[5] adding 30 hp. For 1988, the 2.3 L engine was discontinued; the Aerostar became the first minivan powered exclusively by V6 engines. In 1990, coinciding with the introduction of the E4WD Aerostar, a 4.0 L version of the Cologne V6 was introduced; while standard with all-wheel drive versions, it became an option on rear-wheel drive XLT and Eddie Bauer trims as well.

Sharing its transmissions with the Ford light-truck line, the Aerostar was available with a five-speed manual until 1995 (nearly exclusively in cargo vans and XL trim); unlike the Chrysler minivans, the Aerostar was sold exclusively with overdrive automatic transmissions. In 1997, the 4.0 L V6 became paired with the first five-speed automatic transmission fitted in a US-market minivan.

Exterior

1989–1991 Aerostar XLT

Distinguished by its sloped-nosed design, the Ford Aerostar utilized a "one-box" design similar to the Renault Espace and the Ford Transit; in contrast to its European counterparts, the Aerostar had much shorter overhangs with the wheels placed at the corners. In an effort to further improve its fuel efficiency and aerodynamics and lower its curb weight, several plastic body parts (bumpers, rear hatch) that were utilized in the 1984 concept car were adopted for production.

As a response to the Dodge Grand Caravan and Plymouth Grand Voyager, an (unnamed) extended-length version of the Ford Aerostar entered production for 1989. Sharing the 119-inch wheelbase with the standard-length version, the extended-length Aerostar added 14 inches to the rear body. During the 1990s, the extended-length Aerostar would become the most popular version of the vehicle.

While the Ford Aerostar would never see a full redesign over its 12-year production run, it would see a number of detail changes to bring it in line with other Ford trucks. For 1988, the nameplate badging was changed, moving it from each fender to the tailgate; it was changed from chrome to silver in color. In 1989, the chrome grille was replaced by a black-trim grille; the bracketed towing mirrors were replaced by integrated powered sideview mirrors. In 1992, an extensive facelift redesigned the grille, bumpers, wheels, and replaced the sealed-beam headlights with replaceable-bulb composite units (the amber turn signal lenses were changed to clear-lens units). As it was becoming a federal requirement, a center brake light was added for 1994. As the Aerostar had been slated for discontinuation after the 1994 model year, few visible changes were made afterwards. For 1997, the amber rear turn signal lenses were deleted; XLT models were given optional 14x6" seven-hole alloy wheels.

Interior

In contrast to its radical exterior design, the interior design of the Ford Aerostar adopted many industry-standard features. For example, the seven-passenger Aerostar was configured with the 2-2-3 seating layout popularized in both Chrysler and General Motors minivans. Borrowing features from full-size conversion vans, XLT-trim versions were available with second-row bucket seats; another option allowed both rear bench seats to fold down to make a bed; both rows of rear seats were removable.

However, the interior also featured several European-influenced designs: the Aerostar was fitted with a floor-mounted shifter for both automatic and manual transmissions and was equipped with a handbrake (which would become a feature in all US-market Ford minivans); in a fashion similar to the Volkswagen Vanagon, the second-row windows slid open. While cupholders were relegated to an optional armrest in the third-row seats, the Aerostar could be specified with up to six ashtrays and two cigar lighters; the interior may have been designed with a smoker in mind.

In 1992, coinciding with the exterior updates, the interior also saw a major upgrade. Along with the addition of a driver's side airbag and three-point seatbelts for all six outboard seats, the dashboard was redesigned with improved controls (many shared with the 1992 Econoline) and a new instrument panel. In 1993, integrated child safety seats were introduced as an option.

Trim

Along with a cargo van (distinguished by its available double rear doors and lack of side windows), the Aerostar passenger van (called the Wagon) came in two trim levels: base-trim XL and deluxe-trim XLT (in keeping with the Ford truck line). Many features standard on the XLT were available as extra-cost options on the XL, such as power windows, mirrors, and locks, air conditioning, and privacy glass.

XLT-trim Wagons also included the following features as extra-cost options:

• Overhead trip computer with auto-dimming rearview mirror (featuring: Distance to Empty (English/Metric), Trip Mileage, Average Fuel Economy, Instant Fuel Economy, Average Speed (English/Metric), along with dual map lights)
• Rear climate control
• Second-row Captain's chairs (quad seats)
• Fold-flat second and third-row bench seatbacks
• 8-speaker AM/FM stereo with cassette player
• Premium AM/FM/cassette sound system with 7-band equalizer and rear-seat headphone jacks
• Rear-wheel anti-lock brakes
• Electronic four-wheel drive (see section)
• Two-tone paint
• 14" aluminum wheels

Eddie Bauer Wagon (1988–1996)

1989 Ford Aerostar Eddie Bauer

Introduced during the 1988 model year, the Aerostar was one of the first Ford vehicles to feature the outdoors-themed Eddie Bauer brand as a trim package. Marketed above the XLT, the Aerostar Eddie Bauer was the first minivan marketed towards luxury buyers (for 1988, the Chrysler Town & Country was produced as a compact station wagon, not becoming a minivan until the 1990 model year).

The Eddie Bauer trim combined the interior convenience features of the XLT trim with two-tone exterior paint (tan as the accent color on the rocker panels and wheel trim) and a tan outdoors-themed interior. As on the XLT, cloth seating surfaces were standard; as part of the 1992 update, leather seats became an option. A standard feature of the trim package (an option on the XLT) was a feature allowing the second and third row bench seats to fold flat into a large bed across the rear half of the interior. However, a large number of Eddie Bauer Aerostars were ordered with the optional second-row bucket seats/captain's chairs.

Following the introduction of the extended-length wagon in 1989, the Eddie Bauer trim was available in both body configurations. After 1989, the option package came with the 4.0L V6 standard, though buyers could choose between rear-wheel drive and all-wheel drive powertrains.

After the 1996 model year, the Eddie Bauer trim was discontinued as the Aerostar trim line was consolidated to the cargo van and the Aerostar XLT.

Aerostar Sport (1992–1996)

1992–1996 Ford Aerostar XL Sport

In 1992, the Aerostar Sport was introduced as an option package available for any non-Eddie Bauer Aerostar Wagon. Similar to its Chevrolet Astro RS/GMC Safari CS and Dodge Caravan ES counterparts, the Aerostar Sport was largely a cosmetic upgrade. Distinguished by their silver-accented paint and "Sport" pinstriping, the Sport featured integrated running boards with a color-matched front air dam and color-matched rear mud flaps. On darker colors, the front grille and chrome was painted body color.

The trim version of an Aerostar Sport is most easily identified by its wheels: XL Sport Wagons, with full wheel covers; XLT Sport Wagons (less common), with aluminum wheels.

Ford Aerostar (1984)

The Aerostar name was first revealed as a concept vehicle was shown in 1984,^[3] with Ford predicting up to 40 mpg in production versions with four-cylinder diesel engines.^[3] With a drag coefficient of Cd=0.37, the Aerostar was one of the sleekest vehicles designed by Ford, besting the Ford Mustang SVO and the Lincoln Continental Mark VII.

Ford engineers chose the front-engine layout for a variety of reasons. In terms of safety and engine access (in comparison to German and Japanese imports), the company found that potential buyers preferred the configuration over rear and mid-engine vehicles.^[3] Ford also chose a rear-wheel drive layout for the Aerostar; this provided it with a 5,000 pounds (2,300 kg) tow rating, 2½ times the capacity of the Chrysler vans.^[3][4]

In the change from concept to production, very little of the exterior design would change, except for the window glass, headlights, and grille.

HFX Aerostar Ghia (1987)

Introduced at the 1987 Frankfurt Auto Show,^[6] the HFX (High Feature Experimental) Aerostar Ghia was a prototype of future minivan design. Two running prototypes were built from the collaboration of Ford and Ghia;^[7] both used the stock 3.0L Vulcan V6 and A4LD automatic transmission. The HFX concept borrowed some features used in other Ford vehicles, such as four-wheel air suspension and electronic climate control. From there, some of the technologies showcased in the HFX had never before been seen in a minivan; this included run-flat tires, adjustable pedals, power-sliding side doors, electric power steering, ABS, traction control, seatbelt pretensioners, and movable grille shutters.^[7] On the rear, an LCD display was installed for the use of displaying 12 pre-programmed warning messages.^[7]

Link to HFX Aerostar Ghia images.