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Thread: Aerostar aluminum drive shaft

  1. #1
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    Default Aerostar aluminum drive shaft

    Ive looked and looked and have more info than I know what to do with. I want to get an Aluminum drive shaft. The stock one is an inch short. I have swapped in a tko 600 and I'm looking at slicks and want a proper length drive shaft.
    I know that an aerostar has been a donor in the past and have found guys that have done it in a mustang.
    The problem I need help with is the year and length I plan on cutting it and welding just need a good starting place .
    I can get one made for $400 but the cars getting painted and I just bought a tremec and now I'm broke so $400 is out for a while


    Thanks Westie

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    Crown Vic cop car or taxi drive shaft, cut down, and use the adaptor u joints. Done.

    The Aerostar shafts are smaller, and a lot harder to find. 400 dollars to make it, or just to cut down a shaft for you??? I found a place 100 miles from me that'll do em for 75 apiece...

    IIRC the AWD aerostar shaft is a direct fit for a stang, not a Tbird. And like I said, the cop/taxi Vics are everywhere...I can nab the shaft for 20 bucks at my local pick n pull.
    '84 Mustang, work in (sloooooooow) progress...
    '87 Stang notch
    1994 Ford F150 Flareside
    1997 Explorer V8 conversion (in progress)
    1998 Explorer 5.0
    and a couple of tractors. Ford, of course.
    FORD power, for life!

  3. #3
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    I got mine from a Crown Vic cop car for free. Performance drivetrain in Oklahoma City took my aluminum drive shaft from the Vic, my yoke and flange from the Sport's spare drive shaft, and used the adapter u-joints as mentioned above and then a nice cut and balancing and I was good to go. It's 4 inches in diameter, a lot bigger in diameter than the stock shaft, so watch your mufflers. It weighs a little more than nothing.
    '88 Sport--T-5,HURST shifter,TMoss GT-40 intake,Ed Curtis cam,Trick Flow heads,Scorpion rockers,70mm t-body,3G,mini starter,Taurus fan,BBK headers,O/R H-Pipe, Flowamaster 40's, deep and deeper Cobra R wheels,Mass Air, Mass Air and 24's,8.8 with 3.73's,140 mph speedo,Mach 1 chin spoiler,SN-95 springs,CHE control arms,aluminum drive shaft and a lot more..

  4. #4
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    Quote Originally Posted by ThunderbirdSport302 View Post
    Crown Vic cop car or taxi drive shaft, cut down, and use the adaptor u joints. Done.

    The Aerostar shafts are smaller, and a lot harder to find. 400 dollars to make it, or just to cut down a shaft for you??? I found a place 100 mv
    iles from me that'll do em for 75 apiece...



    IIRC the AWD aerostar shaft is a direct fit for a stang, not a Tbird. And like I said, the cop/taxi Vics are everywhere...I can nab the shaft for 20 bucks at my local pick n pull.

    400 to make it. What year vic. Cop ones better the local yard has a dozen 2000 ish cop cars ?
    Last edited by thewestie; 05-17-2011 at 09:39 AM.

  5. #5
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    Quote Originally Posted by thewestie View Post
    400 to make it. What year vic. Cop ones better the local yard has a dozen 2000 ish cop cars ?
    Yeah, I think one of the ones I snagged was a 2000, the other was a '98...I think they go back several years, too, 95 to current, for alum. shafts...
    '84 Mustang, work in (sloooooooow) progress...
    '87 Stang notch
    1994 Ford F150 Flareside
    1997 Explorer V8 conversion (in progress)
    1998 Explorer 5.0
    and a couple of tractors. Ford, of course.
    FORD power, for life!

  6. #6
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    I got one it's to short for mine, not sure what year it came from. It's about 4" to short. It may fit a stang though.
    Old Grey Cat to this.88 Cat,5.0 HO, CW mounts,mass air,CI custom cam,afr165's,Tmoss worked cobra intake,BBK shorty's,off road h pipe, magnaflow ex. T-5,spec stage 2 clutch,8.8 373 TC trac loc,che ajustables with bullits on the rear.11" brakes up front. +

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    What is the stock length of the drive shaft for a bird?

  8. #8
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    An Explorer aluminum driveshaft will also work, but it to needs to be shortened a little bit, but not much. I think it was either 3/4 or 1 inch too long.
    '88 Sport--T-5,HURST shifter,TMoss GT-40 intake,Ed Curtis cam,Trick Flow heads,Scorpion rockers,70mm t-body,3G,mini starter,Taurus fan,BBK headers,O/R H-Pipe, Flowamaster 40's, deep and deeper Cobra R wheels,Mass Air, Mass Air and 24's,8.8 with 3.73's,140 mph speedo,Mach 1 chin spoiler,SN-95 springs,CHE control arms,aluminum drive shaft and a lot more..

  9. #9
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    Quote Originally Posted by jonwayne1988 View Post
    What is the stock length of the drive shaft for a bird?
    I measured mine today and it was 49" I was having some driveline vibration at higher speeds and traced it to a dent in the driveshaft. I blame Pepboy's since they were the last ones to touch it when they changed my U-joint bearings. I was hoping to upgrade to an aluminum shaft, but I may just order a new stock one since there's no direct fit for our cars.

    turbo charged 94 Cobra engine/440cc injectors/megasquirt /5 speed swapped (T5)/maxbox upper intake/70mm PP throttle body/AJE coilovers/2003 Mustang control arms/S.T. sway bars/ES rear control arm bushings/11" brake conversion/manual rack conversion/8.8 TC rear with rear discs and a welded diff/3.73 gears/PLX wideband/199mph speedometer/Aeromotive FPR/CNC hydraulic hand brake/cobra R wheels/....ect.

  10. #10
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    Mine was cheap to have shortened and balanced, including the new u-joints. Go aluminum.
    '88 Sport--T-5,HURST shifter,TMoss GT-40 intake,Ed Curtis cam,Trick Flow heads,Scorpion rockers,70mm t-body,3G,mini starter,Taurus fan,BBK headers,O/R H-Pipe, Flowamaster 40's, deep and deeper Cobra R wheels,Mass Air, Mass Air and 24's,8.8 with 3.73's,140 mph speedo,Mach 1 chin spoiler,SN-95 springs,CHE control arms,aluminum drive shaft and a lot more..

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