Suspension Design of the Ford Aerostar: Was It Unique in the Minivan Segment?

The Ford Aerostar isn’t often the first name dropped in conversations about minivan innovation, but maybe it should be. From its rear-wheel-drive layout to its truck-like DNA, the Aerostar made some bold decisions that set it apart from its competitors. But perhaps one of its most quietly distinctive features was its suspension setup.

Let’s dive into how Ford engineered the Aerostar’s suspension system, and whether it truly stood apart in the 1980s and 1990s minivan landscape.

A Van with Truck Bones

Before we get under the van, let’s set the stage. When Ford debuted the Aerostar in 1986, it aimed to create something that could straddle the line between passenger car comfort and truck toughness. The company pulled heavily from its Ranger pickup and Bronco II parts bins, especially in the chassis and drivetrain departments.

Most minivans at the time were essentially front-wheel-drive cars with taller roofs. The Chrysler minivans, like the Dodge Caravan and Plymouth Voyager, used car-based unibodies and transverse-mounted engines to maximize interior space and maneuverability. On the other hand, the Aerostar rode on a longitudinally mounted, rear-wheel-drive layout that hinted at its truck lineage, and the suspension told the same story.

Coil Springs All Around: A Unique Choice

From the start, the Aerostar used coil springs at all four corners. This might sound ordinary today, but it was relatively unusual for the era, especially in a segment where cost and simplicity often drove design decisions.

The Aerostar featured an independent suspension with coil springs mounted on short-and-long-arm (SLA) control arms in the front. The rear setup included a live axle with trailing arms and coil springs, a combination that echoed the design of the Ford Ranger but replaced the rear leaf springs typically used in trucks with more comfort-friendly coils.

This design gave the Aerostar a smoother, more composed ride compared to many of its rear-drive competitors, while still retaining the toughness to tow and haul. According to Ford’s original product literature, the van’s suspension was specifically tuned to balance comfort and durability for families and small businesses alike.

How Did It Compare?

Let’s take a look at the main rivals:

Chrysler Minivans

Chrysler’s front-drive minivans used a MacPherson strut setup up front and a beam axle with leaf springs or coil springs in the rear, depending on the year and trim. The strut design offered simplicity and packaging benefits but didn’t provide the same level of ruggedness or serviceability as the Aerostar’s front suspension.

Early Chrysler vans leaned heavily on car-like comfort, but lacked the muscle that rear-drive platforms could deliver. Towing capacity was limited; something the Aerostar trumped with ease.

Chevy Astro and GMC Safari

GM’s Astro and Safari vans, launched in 1985, were perhaps the Aerostar’s closest competitors. Like the Ford, they used a rear-wheel-drive layout, but their suspension was more traditional: torsion bars in the front and leaf springs in the rear.

Torsion bars were great for load-bearing and front-end clearance, but they lacked the ride comfort of coil springs. Leaf springs, while durable and ideal for towing, made for a bouncy and less refined ride. The Aerostar’s all-coil setup offered a more forgiving ride without compromising much on payload or capability.

Performance in the Real World

Drivers and reviewers of the time often praised the Aerostar for its composed handling. According to a 1986 Car and Driver review, the Aerostar “rides more like a sedan than a truck,” a statement that would’ve been unthinkable for many van-based platforms before that point.

The coil-sprung suspension and rear-drive architecture combination gave the Aerostar solid road manners and excellent highway stability, even under load. This was particularly valuable for families traveling long distances and for tradespeople carrying tools and equipment.

Ford even offered optional load-leveling air shocks in later models to improve ride quality and handling when fully loaded, giving the Aerostar more suspension sophistication than most minivans offered at the time.

A System Built for Versatility

What made the Aerostar’s suspension unique wasn’t just its coil spring setup, but how that system fit into a larger design philosophy. Ford wasn’t trying to make another people-mover. They offered something tougher, more capable, and could handle a pop-up camper just as easily as soccer practice.

By using a configuration that balanced comfort and utility, the Aerostar filled a niche that Chrysler and GM didn’t directly address: the dual-role minivan that could work during the week and play on the weekends.

Conclusion: A Quietly Innovative Ride

While suspension design might not be the flashiest feature in a vehicle, it has a massive impact on how a van drives, rides, and handles day-to-day life. In that regard, the Ford Aerostar quietly innovated. Its coil springs at all four wheels, combined with a truck-inspired chassis, made it one of the most versatile and balanced minivans of its time.

Whether you’re an enthusiast looking back or a collector hunting for vintage Ford engineering, the Aerostar’s suspension system deserves recognition. It may not have dominated the minivan sales charts, but it left a unique treadmark in the history of family haulers.