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

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    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

    Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Cooling System Bleed -> 1997 Expedition, Econoline & F-Series -> Aerostar, Explorer & Ranger -> Bronco, 1996 Econoline & F-Series -> Villager -> Windstar
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Bronco, 1996 Econoline & F-Series

    Disconnect heater outlet hose at water pump to bleed air from the system. When coolant begins to flow, reconnect heater hose. Start engine and allow to warm up. Shut engine off and allow system to cool. Remove radiator cap and fill with coolant as needed.

    1997 Expedition, Econoline & F-Series

    Fill cooling system with a 50/50 mixture of coolant and water, then place heater temperature selector in the maximum heat position. Start engine and allow vehicle to warm up. Add coolant, as required, to maintain coolant at the f...

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

    BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Disc Brakes -> Description -> Aerostar, Explorer & Ranger -> Bronco, E-150 & F-150 -> E-250-350, F-250-350 & F-Super Duty, Front -> F-Super Duty, Rear -> Villager -> Windstar
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Aerostar, Explorer & Ranger

    These models use a pin sliding caliper type system, Fig. , in which the caliper slides on two pins attached to the spindle assembly.

    Bronco, E-150 & F-150

    These models use the LD (Light Duty) pin rail sliding caliper type system, Fig. , in which the single piston caliper slides on two pins attaching the caliper to the spindle assembly.

    E-250-350, F-250-350 & F-Super Duty, Front

    These models use the HD (Heavy Duty) pin rail sliding caliper type system, Fig. ,...

    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 Filter Replacement -> Except Diesel Engines & Villager
    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 has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.

    On model...

    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 U-JOINT, Replace -> Assemble -> Disassemble -> Double Cardan -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    Single Cardan, Slip Yoke

    Disassemble

    Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

    • Index-mark the shaft components.
    • Remove and discard all four snap rings.
    • Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
    • If necessary, use a pair of pliers to remove a bearing cup t...

    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 3.0 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 -> Charge System Warning Indicator ->
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    The charge system warning indicator lamps are used to warn of no alternator output. When ignition switch contacts are closed, current flows through charge indicator and pa...

    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...

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    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+.

    Instrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar  4.0 V6 GASInstrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar 4.0 V6 GAS

    Components on diagram:
  • Transmission Control Switch
  • Inertia Fuel Shut-Off Switch
  • Wiper Control Module
  • Radio
  • Instrument Cluster
  • Body Connector & Component Locations w/Rear Door & Hatch Connector Locations Diagram for 1996 Ford Aerostar  3.0 V6 GASBody Connector & Component Locations w/Rear Door & Hatch Connector Locations Diagram for 1996 Ford Aerostar 3.0 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
  • 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  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • A/C-Heater Control Assembly
  • A/C Clutch Field Coil
  • Clutch Cycling Pressure Switch
  • A/C Wide Open Throttle (WOT) Relay
  • High Pressure Cutoff Switch
  • 1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Illumination
  • Liftgate Washer Pump Motor
  • Liftgate Wiper Motor
  • Liftgate Wiper Washer Switch
  • 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 1997 Ford Aerostar Antenna1997 Ford Aerostar Antenna, 4-section mast; 1200 mm cable; With top and side key; A high quality universal fender mount antenna; May require modification or other adjustment to your vehicle upon installation; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $5.62

    Click here to view more details about 1994 Ford Aerostar Starter1994 Ford Aerostar Starter, PMGR type; 1.4 kW torque output, 12 V, clockwise rotation, 10 teeth; A high quality, direct fit OE replacement starter; No core required..

    Source: Auto Body Parts Store

    $86.04

    Click here to view more details about 1997 Ford Aerostar Park Lamp Assembly Passenger Side1997 Ford Aerostar Park Lamp Assembly Passenger Side, Parking Lamp Assembly; Passenger Side; In Fender, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $20.45

    Click here to view more details1987 Ford Aerostar L4, 2.3 L, 140 CID Rebuilt Engine, FI, roller rockers, flat bottom intake ports, heart shaped combustion chamber, flat rear main cap, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,435.00

    Click here to view more details1994 Ford Aerostar Used Parking Lamp, Driver Side, Parklamp/Turn Signal; (outer hdlp mtd), Very Good.

    Source: Used Auto Parts Store

    $45.00

    Click here to view more details1991 Ford Aerostar Used Steering Gear, 3.0, AUTO, RWD, PS Power Rack & Pinion, Very Good.

    Source: Used Auto Parts Store

    $131.00
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