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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!
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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

Electrical Symbol & Wire Color Code Identification -> Wire Color Code Identification -> Domestic Vehicles
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Anti-lock Brakes -> 1993-96 Aerostar, E-Series, F-Series & Ranger (RABS) -> System Service -> Aerostar -> Brake System Bleed -> Component Replacement -> E-Series -> F-Series -> Installation -> RABS II Module -> Ranger -> Rear Wheel Speed Sensor -> Removal -> Speed Sensor Ring
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

Brake System Bleed

The RABS II master cylinder and hydraulic control unit must be bled using anti-lock brake adapter tool No. T90P-50-ALA and jumper tool No. T93T-50-ALA, or equivalents. If this procedure is not followed, air will be trapped in the hydraulic control unit and will contribute to improper brake pedal feel.

Bleed system as follows:

  • Place bleed/harness switch on bleed adapter tool to bleed position.
  • Turn ignition switch to On position. At this point, the red OFF indicator should turn on.
  • Push motor button on the adapter down. This starts the pump motor.
  • The red OFF indicato...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1994-97 Aerostar -> Normal Service -> Severe Service
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Normal Service

Replace every 30,0...

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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...

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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 ...

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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Trucks -> Rear Load Leveling (CHECK SUSP) ->
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

The CHECK SUSP indicator lights when there is a fault of the rear load ...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Lower

  • Drain cooling system into a suitable container.
  • Reposition hose clamp from radiator.
  • Remove radiator outlet hose from radiator.
  • Reposition hose clamp from water pump.
  • Remove radiator outlet hose from water pump and from vehicle.
  • Reverse procedure to in...

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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, ...

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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 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
  • 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:
  • Transmission Control Switch (TCS)
  • PCM Power Relay
  • Mass Air Flow (MAF) Sensor
  • Transmission Control Indicator Lamp (TCIL)
  • Powertrain Control Module (PCM)
  • 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 Grille Assembly1991 Ford Aerostar Grille Assembly, With emblem provision, chrome molding, and black grille insert; A high quality, OE replacement complete grille and shell assembly; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $13.37

    Click here to view more details about 1997 Ford Aerostar Fan Blade1997 Ford Aerostar Fan Blade, 9 blades; A high quality, OE replacement radiator fan blade; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $38.92

    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 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 details1996 Ford Aerostar Used Air Flow Meter/Sensor, 3.8, AUTO, RWD 6-232 (3.8L), Very Good.

    Source: Used Auto Parts Store

    $85.00

    Click here to view more details1992 Ford Aerostar Used Ignition Switch W/Key, Very Good.

    Source: Used Auto Parts Store

    $55.00
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