Hello Ford Friends, I am joining this group to seek guidance in the rebuilding of my 1993 3.0 V6 Ford Aerostar engine and transmission. My powerplant is still running but I would like to give it a new life, less weight and more HP. On weight, I hope to find replacement cylinder heads made of aluminum, which I believe could save up to 100 lbs on the engine. Does anyone of you have pointers. Where should I do business? Thanks. Philippe.

Phillippe, Try this website. Fred seems to know the Vulcan 3.0 pretty well. http://rogueperformance.com/WelcometoFredland.html   I don't know of any aluminum heads, or any alternate heads for that matter, for the Vulcan. However, the later Vulcans came equipped with roller cams and lifters, as well as composite intake plenums. They're rated at 155 HP vs. 140 for the older Vulcans. I'm presently preparing a Vulcan from an '03 Taurus for installation in my '96 Aerostar - main difference is the need to change head gaskets and intake manifolds due to the front to rear drive conversion. Of course, while the heads are off, one can clean the ports up with the ol' Dremel tool, and make a few other changes that Fred recommends.  Everything seems to bolt up the same as the 96 engine, so far. Even the wiring harness is similar. Next unseasonably warm weekend we get here in KY, it's going in. I'll post the full report once completed. These ain't the easiest machines to swap engines from, but not the hardest, either.   Of course, now that you've mentioned this, anyone 'round here ever try putting a SHO or a Duratec in an Aerostar? I have seen a 302 installation, but it required cutting the floorboards around the engine and enlarging the tunnel and rear engine hatch opening. Also, the 3.8 as installed in the Windstar has aluminum heads - it's a 90-degree V6 and may have its banks spread too far to fit, but I bet the harness would interchange, if you could also get the computer for it.  - AC

AC, Thanks for taking the time to respond to my post. I will go and visit the site that you are suggesting. As a follow-up to my own questions I should feedback to this group what I heard on the Ford Truck enthusiasts Forum where I had asked the same question. They told me that there was no such a thing as alloy heads for the Vulcan, I would have to cast them myself. The other piece of interest is my visit of a significant website: www.performanceprobe.com. One forget that the Ford V6 3.0 was in 1990-92 a Ford Probe option called LX. Anyone contemplating engine rebuilding or upgrading should visit this page and the links. At this point I have decided to follow your suggestions about the rockers, and to improve the complete exhaust line, admission line, maybe buy an alloy flywheel and a lighter clutch. I am confident that I will be able to pusch the vulcan to 170 HP that way...and this is about all I need. Take care. Philippe.