my 1996 AWD Ford Aerostar flex plate keep cracking?

Are you buying flex plates from advance auto or auto zone? They usually only stock the absolute lowest end product unless you special order.

One reason might be the crankshaft thrust washers are incorrect allowing the crankshaft to move back and forth. Another might be the wrong starter as you have different splines that require the exact match starter with flex plate. Possibly too, the transmission or motor mounts are worn out allowing things to flex enough to put pressue on the flex plate and crack it. Or transmission bell housing bolts were loose, torque converter could cause it too. Really need to have a GOOD mechanic check it out to find the culprit. Stay away from national chains and super center stores as those guys are far from ever being mechanics for the most part.

Kegan, it ought to be a number of issues. There could be a misalignment the place the transmission bolts to the engine, despite if this is fairly uncommon on older automobiles like yours. The crankshaft in the engine ought to be strolling back and forth as a results of fact of a worn thrust beaing or worse. this is basic to make certain, only attempt to pry the crankshaft back and forth. There ought to be in ordinary terms a marginally perceptable action. There ought to be something incorrect with the transmission or the torque converter. different issues ought to reason it, yet those are the main common.

where does it crack?

were the mating surfaces completely free of debris?

was it torqued in sequence and to the right foot-pounds?

was it mated to the torque converter properly?

are the starter mounting holes hogged out?

Make one. Out of steel