.1991 Ford Aerostar 4.0 Lt engine, auto tran', electrical short ?

Because it is a 1991 Ford Aerostar.... STEVE, you have so many areas that need to be checked, it will require a technician.
Why? It could be your GAS (old and water in the fuel), ignition shorts, Vacuum adjustments, plugs, plug wires, fuel pump, clogged lines, battery, battery posts are corroded, battery cables are bad, and lots more.

If the engine cranks but has no spark, you need to know if the coil is getting voltage and a ground signal. The coil gets power from the ASD relay and a fuse.
Have you checked the compuer for trouble codes ?

1994 Ford AEROSTAR Recall ID from NHTSA: 99V028000 Auto Recall Date: 02/09/1999
Vehicle Component: ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
Estimated Vehicles Affected: 23097
1994 FORD AEROSTAR Defect Summary:
VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.
Defect Consequence:
HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.
Remedy:
DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.
Notes: FORD MOTOR COMPANY, 99S01 1994 Ford AEROSTAR Recall ID from NHTSA: 97V204000 Auto Recall Date: 11/13/1997
Vehicle Component: POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)
Estimated Vehicles Affected: 75000
1994 FORD AEROSTAR Defect Summary:
VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT BUSHING DISPLACEMENT CAN RESULT IN STRUCTURAL FAILURE OF THE TRANSMISSION AND/OR TRANSFER CASE. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Defect Consequence:
THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Remedy:
DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
Notes: FORD MOTOR COMPANY, 1994 Ford AEROSTAR Recall ID from NHTSA: 99V029000 Auto Recall Date: 02/09/1999
Vehicle Component: ELECTRICAL SYSTEM:IGNITION:SWITCH
Estimated Vehicles Affected: 762201
1994 FORD AEROSTAR Defect Summary:
VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES WERE PRODUCED WITH A HIGHER THAN SPECIFIED ELECTRICAL LOAD THROUGH THE ACCESSORY POWER FEED CIRCUIT. THE POTENTIAL FOR CONTACT BETWEEN THE B2 (BATTERY), A2 (ACCESSORY), AND P1 (PROOF) CIRCUITS CAN OCCUR, CREATING A SHORT CIRCUIT, ALLOWING CURRENT TO FLOW THROUGH THE GROUND WIRE.
Defect Consequence:
THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.
Remedy:
DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.
Notes: FORD MOTOR COMPANY, 99S02 1994 Ford AEROSTAR Recall ID from NHTSA: 98E010000 Auto Recall Date: 04/08/1998
Vehicle Component: SERVICE BRAKES, AIR:DISC:ROTOR
Estimated Vehicles Affected: 23500
1994 FORD AEROSTAR Defect Summary:
EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
Defect Consequence:
LOSS OF BRAKING CAN RESULT.
Remedy:
AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
Notes: AIMCO PRODUCTS INC., 1994 Ford AEROSTAR Recall ID from NHTSA: 06E022000 Auto Recall Date: 03/13/2006
Vehicle Component: SERVICE BRAKES, HYDRAULIC
Estimated Vehicles Affected: 7440
1994 FORD AEROSTAR Defect Summary:
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Defect Consequence:
LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy:
AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
Notes: BRAKE PARTS, INC

Sounds like a bad alternator. Most auto part stores will check these for free. All you have to do is get it off the van (which I know is no easy feat)

The 7.3 in that year is one of the better ones.
Not much electronics to go wrong.
It is not a Ford engine but a International Truck diesel engine.
It is also used in many larger trucks and racks up high mileage with few problems.
Yours at 200km is almost.......just broken in!

The transmission is the weakest point in the drive line.......run a good BIG trans cooler if you are hauling heavy loads and stay out of overdrive when pulling or hauling anything heavy.

your transmission is no good

I would suggest you goto www.kbb.com and just double check .. I am not sure of the actual model so I "winged it" and that price is $500 above the model (1991 Ford Aerostar Window Minivan) Excellent shape price for my area ..

I dont think so, no. The transmission in the 4.0 L is a standalone tranny made by Ford. I BELIEVE that the 3.0 L engine uses the same transmission that is used in the Ford Ranger.

I am no mechanic, but I cant see a direct correlation between an electrical short and overheating.
I had a bad water pump on my van and never overheated due to the mechanical fan that is on the main shaft that turns the pullies and such.
Sounds, unfortunately, like a freak coincidence. Sorry

It's right next to the air filter and behind the radiator fan and to the right of the oil dipstick. The transmissions is black and the oils is yellow. If it's a manual, there's no dipstick there. If not check close to the forewall towards the back of the engine.