On another Aero site a man reports he used a Sawzall to just cut the outlets off after getting the core loose. He then enlarged the heater hose holes and put the new core in using regular hose clamps. He claimed it saved a lot of time and trouble. I have not had to do this repair and can't comment on it, but here it is FWIW. Ray Mac.

Bill sent me a scan of his Haynes and they do indeed show an AC style (similar) formed hose in his diagrams - I've never seen a hose like that after 20 yrs of specialized military equipment, tractor trailers, farm equipment, etc...weird but it must be true. My 86/2.8l, 95/3.0l and 96/3.0l all have the standard clamps on cut to fit hose.    

I had to do something just as extreme to remove the heater core on my 88 Tbird, had to cut the fire wall on the engine compartment side so to remove the core without having to remove the dash and A/C box, the job also calls for the A/C refrigerant to be removed if I recall correctly. Now that will be a nightmare to do, on the average it is a $300.00 + parts to have a shop do it for you.   Jaime
88 TC.
On another Aero site a man reports he used a Sawzall to just cut the
outlets off after getting the core loose. He then enlarged the heater
hose holes and put the new core in using regular hose clamps.
He claimed it saved a lot of time and trouble.
I have not had to do this repair and can't comment on it, but here it
is FWIW.
Ray Mac.

Note the position of the vacuum actuator, it is pointing backwards wen properly installed.   You will need 2 each of this to be able to install the above valve in to a 94 Aerostar. You will need 4 clamps and 2 pieces of 5/8" heater hose about 3" to 4" long.   If any one knows of a better/easier way to install this valve please input.     Jaime
88 TC. Attachment: (image/jpeg) 74809.jpg [not stored] Attachment: (image/jpeg) 5047094.jpg [not stored]