- > Currently I am getting 27.7 mpg city/highway average > and 30 + without using the AC, with the following > mods. Keep in mind that I am here in San Antonio TX. > and we do not have a smog test yet. You are already getting unheard-of mileage. > 1- Relocated TFI module to the front of the van, so > to keep it cool so the van does not die/stall on hot > days. ** What is the 'TFI module' ? > I am also using the distributor that goes > along with this setup, can't remember the year > model, I think it is 93 up?

TFI = to Thick Film Ignition, it is the module that is bolted to the distributor on the earlier models. Later, Ford finally moved it to the engine compartment passenger side next to the AC box. On my 88 Aerostar the TFI module was attached to the distributor, on very hot days the TFI module will overheat since the engine transfer heat to the distributor the heat that the TFI module generates on its own will not dissipate and the module will fail. This failure will leave you stranded at best or in the middle of an accident if you happen to be in the way of some one when the engine dies. So to correct the problem I swapped in the later model ignition setup distributor and remote harness for the TFI module. No more TFI module failures. To think that Ford did not want to admit in to the problem in the first place, maybe because it is a problem that will show up more in the southern states where it gets hotter in the summer.   So I am already getting very good gas mileage? then this is good! I was thinking that it could be improved on. The van had always done around 16 to 18 miles to a gallon, but since the gas prices started to climb and my wife is using it more because she got a job. It started hitting the pocket hard.   On one of my day's off from work I was able to get a hold of the van and do a code scan KOEO (Key On Engine Off) and came up with a code 86 something about the 3-4 shift solenoid circuit failure, long story short to replace this solenoid the AT valve body has to be removed and separated, I ended up having to replace the complete valve body since the gaskets where so old they just crumbled to pieces. So to the Junk Yard I went, got lucky and found a valve body that was in better shape than mine with good solenoids. $52.00 later + ATF and a new filter the van is running again and shifting like it is supposed to.   Yea I will admit that that tire pressure is a little high, yet as long as I do not go on a long trips, it is OK for short trips around town. On long trips I lower the pressure to about 37 psi once the tires heat up the pressure goes up to about 40 psi. Oh yea no one should try this with tires that have been run under inflated, they tend to separate and the extra pressure will deform them and cause them to vibrate just before they explode or loose the tread.   I am not aware of the tire pressure insurance thing yet something to check on. I am yet to see an Aerostar that wear the tires in the middle, I will keep you guy's posted on how it goes with mine, it will be a year next July since I have been running the tires like this. Hey it works for me YMMV (Your Mileage May Vary).    So the Tempo starter will more or less fit the Aerostar is this on a 3.0L. Oh yea did you checked the old mounting plate for wear before you swapped it in to the new starter? If there is a lot of wear this may cause early failure to the starter or the fly wheel because of miss alignment/play. Thanks for the hint on the starter.   Jaime
88 TC. -
> Currently I am getting 27.7 mpg city/highway average
> and 30 + without using the AC, with the followin

Where did you get the later model ignition setup distributor and remote harness for the TFI module? I have an 87 Mustang 5.0 with the TFI module on the side of the distributor.

Ford moved ALL the TFI modules off the distributor starting about 91.

In your case you need to look for a Ford Thunderbird or Cougar, it will have all you need. Below is a write up of mine from a while back when I did this to my 88 Thunderbird Turbo Coupe. Keep in mind the TC is a 4 banger and your Mustang is an 8, so substitute 4 cyl. for 8 cyl. You will not need to swap distributors.   The epoxy glue mentioned below has to be the non conductive type. I have pictures of the finished assembly/harness some where if I find them I will post them on the files section.   OK I got it sorted out. Actually it is simpler than you may think.

The only changes are that you need to use a 4cyl. TFI module, so do not get
the 6cyl. one it is not going to work.

Get the remote TFI wiring harness from a Mercury Cougar 3.8L from the TFI
connector at the front radiator support frame to where it goes in to the
main computer harness behind the passenger strut tower. Also get the TFI
heatsink leave the 6cyl. TFI you will be using your 4cyl. instead, by the
way it bolts right up to the heatsink once the spade connectors that would
normally go in to the distributor are grounded off and sealed with epoxy so
there is no shorts.

You need to identify the wires that will be soldered to the stock TFI
connector as follows = Ignition ground, IDM, Spout, Power, Start, PIP and
solder them to the corresponding wires from the stock connector. Note the
Ignition Ground wire, PIP and Power will need a jumper soldered to them with
spade connectors that fit the female spade connectors in the PIP assembly in
the distributor. Once this is done all you have to do is take your old 4cyl.
TFI and like I said above cut the 3 spade connectors off from the side of it
then grind them smooth so the module will fit in the heatsink, but before
seal the connectors that where ground off with epoxy so there will be no
shorts. Then apply some heatsink compound (bird shit) to the heatsink and
the back of the TFI module to promote heat transfer to the heat sink.

Remove the distributor from the engine after setting the timing to # 1 spark
plug at TDC, then remove the TFI module and insert the spade connector in to
the PIP module from left to right Ignition Ground, Power, PIP secure the
wires so they do not get pulled out accidentally. Then solder the other
wires as mentioned before. Bolt up the remote TFI and heatsink assembly on
the front of the radiator support frame. Note 88 TC have the bolt on nuts in
place already. Other vehicles will have the holes drilled.

Insert the distributor back in the engine and align the rotor with the cap's
# 1 spark plug, bolt down the distributor loose enough to be able to adjust
base timing. Install cap and start the engine, set base timing SPOUT
disconnected and you are done.
  Jaime
88 TC.
Where did you get the later model ignition setup distributor and remote
harness for the TFI module?
I have an 87 Mustang 5.0 with the TFI module on the side of the
distributor.

Thanks Jaime