If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing deferential clutch kit. An updated differential clutch kit available.
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Repairpal verified 1995 Ford Aerostar problems
The synchronizer shaft for the camshaft position sensor can cause a loud squeak or chirping noise due to failure of the upper bushing. The noise may be erratic and is usually present when the engine is warm.
If you experience poor idle quality and fuel economy (and the Check Engine Light illuminates) after the exhaust system or motor has been removed and replaced, it could be that the oxygen sensor wires are crossed at the rear of the motor. Wiring schematics should be checked to ensure that the correct harness plug is connected to the corresponding sensor.
The radius arm bushings may wear prematurely due to oil leaking onto the bushings; this causes a loud clunk when the vehicle is shifting gears or stopping.