Auto Parts Search


      Over 40 million used auto parts online. Shop online for auto and truck parts and save up to 75%

1996 Ford Aerostar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

Help me findSearch

Select Section

Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1996 Ford Aerostar car and truck repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Ford Aerostar automobile. Try the Automotix DIY solution today!
DIY REPAIR SAMPLES > CONTINUE EXPLORING >
Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Ford mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 1996 Ford Aerostar vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

General Service Domestic Vehicles -> 1996-97 -> Oil Charge -> Achieva, Grand Am & Skylark -> Aerostar, Explorer, Ranger & Windstar -> Aspire & Probe -> Avenger & Sebring Coupe -> Beretta, Corsica, Aurora & Riviera -> Bonneville, Eighty-Eight, LeSabre, Ninety-Eight, LSS, Park Avenue & Regency -> Breeze, Cirrus, Sebring Convertible & Stratus -> Camaro & Firebird -> Caprice, Impala SS & Roadmaster -> Catera -> Cavalier & Sunfire -> Cherokee, Dakota, Full Size Pickups, Grand Cherokee & Wrangler -> Colt & Summit -> Colt Vista & Summit Wagon -> Concorde, Intrepid, LHS, New Yorker & Vision -> Corvette -> Cutlass Ciera, Cutlass Cruiser, Century, Cutlass Supreme, Lumina, Monte Carlo, Grand Prix, & Regal -> DaimlerChrysler Corp. -> DeVille, Eldorado & Seville -> Econoline -> Escort & Tracer w/1.8L Engine -> Except Aspire, Probe, Escort & Tracer w/1.8L Engine -> Except Tracker -> F-Series, Bronco & Villager -> Fleetwood -> Ford Motor Company -> Full Size Vans -> General Motors Corp. -> Geo Tracker -> Light Trucks & Vans -> Malibu -> Metro & Prizm -> Minivans -> Neon -> Passenger Cars -> Saturn -> Stealth -> Talon
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

DaimlerChrysler Corp.
Passenger Cars

Before installing replacement compressor, drain oil from replacement and failed compressors (drain oil from suction port). Add same amount of oil to replacement compressor as drained from failed compressor.

Remove defective components. Add the proper amount of oil to each replacement component. Most recovery/recycling equipment will measure the amount of oil being removed. This is the amount of oil to be added back to the system, follow manufactures instructions provided with the recovery/recycling station.

Concorde, Int...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar A/C & HEATER SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Power Brake Units -> Bendix Vacuum Brake Booster -> Power Brake Unit Service
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

The Bendix vacuum brake booster unit is se...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar BRAKE SERVICE PROCEDURES

FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.

The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.

After the battery ...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar FUEL FILTER REPLACEMENT PROCEDURES

DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

DRIVESHAFT, Replace -> Front -> Install -> Rear -> Remove
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Front

Remove
  • Mark driveshaft and axle companion flanges as well as driveshaft boot and transfer case front output, so driveshaft can be reinstalled in same position.
  • Release Oetiker low-profile clamp on driveshaft boot with boot clamp pliers tool No. D87P-1090-A or equivalent and free boot from transfer case.
  • Remove axle snubber from beneath pinion.
  • Remove four bolts retaining front driveshaft to front axle companion flange.
  • Remove nuts from transmission mount studs in front crossmember.
  • Raise (jack) transfer case so transmission mount studs are almost out of front crossmember.
  • Slid...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES

STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Starter, Replace
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

  • Disconnect battery ground cable.
  • Raise and support vehicle.
  • Disconnect starter relay to starter electrical cable.
  • Remove starter motor ...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar STARTER & ALTERNATOR REPLACEMENT PROCEDURES

MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Trucks -> Traction Control System Warning Lamp ->
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the warni...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar MAINTENANCE LAMP RESET PROCEDURES

RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Radiator, Replace
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

  • Drain cooling system into a suitable container.
  • Remove rubber radiator overflow hose from radiator.
  • Remove two fan shroud attaching screws, then lift fan shroud out of lower retaining clips and drape over fan.
  • Loosen radiator upper and lower hose clamps, then remove upper and lower radiator hoses from radiator connectors.
  • On models equipped with automatic transmission,proceed as follows:
    • Disconnect and plug two transmi...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar RADIATOR & HOSE REPLACEMENT PROCEDURES

SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

  • Raise tensioner by turning counterclockwise, then remove belt.
  • Install new be...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar SERPENTINE BELT SERVICE PROCEDURES

COMPONENT LOCATION DIAGRAMS FOR 1996 Ford Aerostar AUTOMOBILES

Component location diagrams for most 1996 Ford Aerostar cars and light trucks sold in the U.S. from 1990+.

Body Connector & Component Locations w/Rear Door & Hatch Connector Locations Diagram for 1996 Ford Aerostar  4.0 V6 GASBody Connector & Component Locations w/Rear Door & Hatch Connector Locations Diagram for 1996 Ford Aerostar 4.0 V6 GAS

Components on diagram:
  • Remote Headphone Module
  • Rear Axle Speed Sensor
  • Park Brake Switch
  • Right Rear Door Ajar Switch
  • Left Front Door Ajar Switch
  • Body Connector & Component Locations Diagram for 1996 Ford Aerostar  3.0 V6 GASBody Connector & Component Locations Diagram for 1996 Ford Aerostar 3.0 V6 GAS

    Components on diagram:
  • Right Backup Lamp
  • Left Backup Lamp
  • Rear Auxiliary Blower Motor Switch Illumination
  • Left Rear Turn Lamp
  • Illuminated Entry Timer
  • CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR 1996 Ford Aerostar AUTOMOBILES

    OEM drawn wiring diagrams for most 1996 Ford Aerostar cars and light trucks sold in the U.S.

    1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Throttle Position (TP) Sensor
  • Right Rear Heated Oxygen Sensor (HO2S)
  • EGR Vacuum Regulator (EVR) Solenoid
  • Radio Noise Capacitor
  • Fuel Injector #1
  • 1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Main Light Switch
  • Multi-Function Switch
  • LH/RH Headlamp
  • CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar WIRING DIAGRAMS!

    TECHNICAL SERVICE BULLETINS FOR 1996 Ford Aerostar AUTOMOBILES

    OEM TSB listings for most 1996 Ford Aerostar cars and light trucks sold in the U.S. from 1985+.

    Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Auto Systems:
  • Chassis Electrical, Wiring, Fuses & Breakers, Wipers, Motors
  • Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR 1996 Ford Aerostar AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Ford Aerostar cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO 1996 Ford Aerostar SPECIFICATIONS DATA!

    Shop online for auto body parts, engines, wheels, lights...

    Click here to view more details about 1993 Ford Aerostar Alternator1993 Ford Aerostar Alternator, 95 amps output, 12 V, internally regulated, clockwise rotation, 3 o'clock position; Includes pulley; A high quality, direct fit OE replacement alternator; No core required..

    Source: Auto Body Parts Store

    $116.67

    Click here to view more details about 1997 Ford Aerostar Antenna1997 Ford Aerostar Antenna, 1-section mast; 470 mm extension; Stick-on; A high quality universal imitation antenna; May require modification or other adjustment to your vehicle upon installation..

    Source: Auto Body Parts Store

    $5.01

    Click here to view more details about 1994 Ford Aerostar 14" x 5.5" Steel Wheel1994 Ford Aerostar 14" x 5.5" Steel Wheel, Steel Wheel; 14 X 5.5; 8 Holes; 5 Lug; 4.5 Inch BP; Ident 2L; Black, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    Click here to view more details about 1994 Ford Aerostar V6, 4 L, 245 CID Rebuilt Engine1994 Ford Aerostar V6, 4 L, 245 CID Rebuilt Engine, Aerostar 90-94, Explorer 90-92, Ranger 90-92. If for 90-94 Aerostar, 90-92 Explorer/Ranger with manual trans or 93-94 Explorer/Ranger use FOR-244RLB-1. Supplied with new head casting., Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $2,105.00

    Click here to view more details1986 Ford Aerostar Used Flywheel, B-3000, Very Good.

    Source: Used Auto Parts Store

    $45.00

    Click here to view more details1991 Ford Aerostar Used Grille, CHROME/BLK, Good.

    Source: Used Auto Parts Store

    $88.00
    More parts
    Help me findSearch
    Auto Repair Quick Search
    Help me find
    Search DIY repair manuals by VIN...
    Vehicle Identification Number is a unique serial number used by the automotive industry to identify individual motor vehicles

    Find out what info we have for your vehicle

    Get the Complete Technical Service Bulletins!
    Get the Complete Technical Service Bulletins!Access diagrams and repair information such as wiring diagrams, diagnosis and repair charts, manufacturer service bulletins, and OEM Part numbers of your 1996 Ford Aerostar vehicle.
    Access the Complete guide!
    Need To Fix Your Car or Truck?
    Save Money With Free Car Insurance Quote
    FREE car insurance quote
    Enter Zip Code:
    Auto Repair Quick Search
    Help me find