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I built the Ford aerostar cat converter for ford. the 3.0L has a 2" Y pipe leading to the light off can #1 then a connector pipe leads to #2. Your answer is two. It is a welded system that bolts directly to the r/h and l/h exhaust manifold and the outlet has a welded flat flange with 2" pipe and a 2.250" bolt hole span.

The 4.0L is configured exactly like the 3.0L except the Y pipe diameter is 2.250" vs 2" on the 3.0L. By the way, if your system is rotten you can use a Ranger Y pipe and cobble pipe and catalyst to the muffler inlet pipe. The Aerostar has one fitting for the O2 sensor (EGO) near the crotch of the Y pipe. That sensor is not heated. The Ranger Y pipe will fit your Aerostar perfectly and has one fitting for O2 sensor for that year. It is located in the crotch of the Y pipe. Any Ford cat with a Y pipe has one non heated O2 sensor for both banks until 1996 when OBDII kicked in. This includes F-150/250 trucks under 8500 gvw. After 1996OBDII began each bank got it's own #1 O2 sensor and became heated (HEGO) to reduce emissions at start-up. Ford added a CMS sensor that is generally called position 2 sensor or after cat sensor to monitor emissions. No cheating..you have to have a cat converter on post 1996 cars and trucks.

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Q: How many catalytic converters does the ford aerostar 1997 have?
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