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!

    Automotive Domain Names

    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

    Cooling Fans -> Description -> 1996 -> 1997 -> Aspire -> Continental, Sable & Taurus -> Contour & Mystique -> Cougar & Thunderbird -> Crown Victoria, Grand Marquis & Town Car -> Escort & Tracer -> Mark VIII -> Mustang -> Probe -> Villager -> Windstar
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Aspire

    The cooling fan system consists of an electro-mechanical fan, a temperature switch and a temperature relay.

    The temperature switch, which is located in the thermostat housing, senses engine coolant temperature; while the relay, which is located in the lefthand front corner of the engine compartment between the battery and the headlamp, provides the ground path to complete the circuit.

    When the coolant temperature is below approximately 194°F, the temperature switch is closed, while the relay contacts are held open by magnetism produced in the relay coil. W...

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

    BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Drum Brakes -> Aerostar, Bronco, Explorer, E-150, F-150 & Ranger -> Adjustments -> Drums Installed -> Drums Removed -> Explorer -> Parking Brake Except Rear Disc -> Parking Brake w/Rear Disc -> Rear Disc -> Service Brake
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    Service Brake

    The rear brake shoes adjust automatically when the vehicle is driven in reverse and the brakes are applied sharply several times. Manual adjustment is required only when brake shoes are replaced. When adjusting rear brakes, ensure parking brake is properly adjusted and equalizer is operating freely.

    Drums Removed
    • With drums removed, clean areas where shoes contact backing plate, then apply suitable lubricant to these contact areas. Ensure lubricant does not contaminate linings.
    • Using suitable brake shoe adjusting gauge, adjust gauge to inside diameter of brake drum.
    • Reverse...

    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 3.0 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

    CV AXLE SHAFT, Replace -> Install -> Remove
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Remove

    • Remove front wheel cover/hub cover from wheel and tire and loosen lug nuts.
    • Raise vehicle on a frame contact hoist.
    • Remove wheel and tire, and hub retainer nut and washer. Discard hub retainer nut. It is a torque prevailing design and cannot be reused.
    • Mark differential shaft flange in relation to halfshaft so they may be installed in their original position.
    • Remove four bolts and disconnect halfshaft inboard joint from differential axle shaft flanges. Only four of the six bolts hold CV halfshaft to axle shaft. The other two bolts retain the spacer.
    • Support end of shaft ...

    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 -> Check Fuel Cap Lamp ->
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. If the lamp remains...

    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 3.0 V6 GAS

    • Loosen adjustment and pivot bolts.
    • On models equipped with automatic tensioners,lift tensioner by rotating it counterclockwise.
    • On all models, remove old belts.
    • Install new belts, ensure proper belt groove contact.
    • On models less automatic tensioners, adjust belt tension as follows:
      • Install a suitable belt tension gauge tool, ...

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

    Components on diagram:
  • High Mount Stop Lamp
  • License Lamp
  • Power Mirror Switch
  • Auxiliary A/C System Refrigerant Valve Solenoid
  • Left Rear Seat Speaker
  • 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  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Radio
  • Left Front Speaker
  • Left Rear Speaker
  • Radio Amplifier
  • Right Seat Rear Speaker
  • 1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Brake Fluid Level Switch
  • RABS Proportioning Valve Switch Assembly
  • Windshield Wiper Motor
  • A/C Clutch Field Coil
  • Blower Motor Resistor Assembly
  • 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 1991 Ford Aerostar Alternator1991 Ford Aerostar Alternator, 75 amps output, 12 V, internally regulated, clockwise rotation, 2 o'clock position, 2256 pulley; Replaces OE Ford unit; No core required; A high quality, direct fit OE replacement alternator; May not include pulley..

    Source: Auto Body Parts Store

    $101.21

    Click here to view more details about 1995 Ford Aerostar Oxygen Sensor1995 Ford Aerostar Oxygen Sensor.

    Source: Auto Body Parts Store

    $23.08

    Click here to view more details about 1997 Ford Aerostar Door Mirror Driver Side1997 Ford Aerostar Door Mirror Driver Side, Driver Side Manual Door Mirror, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $49.45

    Click here to view more details1994 Ford Aerostar V6, 3 L, 182 CID Rebuilt Engine, RWD, roller, block # F2DE-BA, head # E6AE-HB, E6AE-HC, CRANK # E6AE-AH, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,611.00

    Click here to view more details1986 Ford Aerostar Used Wiper Motor Front, Very Good.

    Source: Used Auto Parts Store

    $62.00

    Click here to view more details1990 Ford Aerostar Used Air Flow Meter/Sensor, 4.0, AUTO, RWD, Very Good.

    Source: Used Auto Parts Store

    $69.00
    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:
    GOT A WEBSITE?Make money with Automotix

    Make money with Automotix Partner Program.

    Learn more

    Auto Repair Quick Search
    Help me find