1996 Ford Aerostar REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

Auto Parts Search


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

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Accumulator/Drier, Replace -> 1996 -> 1997 -> 1997 Expedition & F-Series -> Aerostar, Bronco, Explorer, Mountaineer, Ranger & 1996 F-Series -> Econoline -> Villager -> Windstar
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

The accumulator/drier must be replaced any time the system has been left open for more than 24 hours with the system completely discharged, there is evidence of moisture in the system, the system is badly contaminated, there is more than five ounces of compressor oil in it, or the accumulator/drier is restricted, plugged or perforated. Replacement of a refrigerant line or a major component (condenser, evaporator or seized compressor) requires replacement of the accumulator/drier. The receiver/drier does not necessarily need to be replaced every time there is a los...

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

BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Hydraulic Brake Systems -> Description -> Combination Valve -> Height Sensing Proportioning Valve -> Hydraulic Control Valves -> Integral Bypass Proportioning Valve -> Master Cylinder
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Master Cylinder

The master cylinder consists primarily of a hydraulic cylinder, primary and secondary hydraulic pistons and a single or dual chamber fluid reservoir. The front brakes are connected to the primary outlet port(s) and are actuated by the primary piston assembly. The rear brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly.

Hydraulic Control Valves

Combination Valve

This multi-function hydraulic control unit consists primarily of a pressure differential valve, brake lamp warning switch and a proportioning valve. A pressure diff...

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 -> Component Locations -> 1985-97 Aerostar 2.3L & 3.0L Engines
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

R...

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

Alternator, Replace
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

  • Disconnect battery ground.
  • Remove snow and ice shield.
  • Remove air intake shield.
  • Disconnect wire harness attachments to alternator assembly.
  • Remove wiring connector brackets.
  • Loosen drive belt ten...

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 -> Low Oil Level Warning Indicator ->
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

This system is used to indicate a low engine oil level condition. The lamp should light during engine starting. If oil level is sufficient, the lamp should go off when engine is operating. If oil level is low the...

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

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...

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/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:
  • 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:
  • Radio Headphone Module
  • Radio
  • Left Rear Seat Speaker
  • Left Front Speaker
  • Right Rear Seat Speaker
  • 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 1995 Ford Aerostar Tail Light, Passenger Side1995 Ford Aerostar Tail Light, Passenger Side, Bulbs not included; DOT and SAE approved; A high quality, OE replacement tail light; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $79.08

    Click here to view more details about 1997 Ford Aerostar Tail Light, Passenger Side1997 Ford Aerostar Tail Light, Passenger Side, Bulbs not included; DOT and SAE approved; A high quality, direct fit OE replacement tail light..

    Source: Auto Body Parts Store

    $50.66

    Click here to view more details about 1997 Ford Aerostar 14" x 6" Steel Wheel1997 Ford Aerostar 14" x 6" Steel Wheel, Steel Wheel; 14 X 6; 8 Slots; 5 Lug; 4.5 Inch BP; Silver, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    Click here to view more details about 1986 Ford Aerostar V6, 2.8 L, 171 CID Rebuilt Engine1986 Ford Aerostar V6, 2.8 L, 171 CID Rebuilt Engine, Ranger, Aerostar, Bronco II, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,487.00

    Click here to view more details1992 Ford Aerostar Used Ignition Switch W/Key, (elect switch only), Very Good.

    Source: Used Auto Parts Store

    $75.00

    Click here to view more details1994 Ford Aerostar Used Fan Blade, 10 blade (super cooling), w/AC, Very Good.

    Source: Used Auto Parts Store

    $72.00
    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