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

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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

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Fixed Orifice Tube, Replace -> Except Villager -> Installation -> Removal -> Villager
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Except Villager
  • Recover refrigerant as outlined under .
  • Disconnect and cap liquid line from evaporator core inlet tube using spring coupling tool.
  • Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet tube.
  • Using tool T83L-19990-A, or equivalent, engage with the two tangs on the orifice tube, Fig. . Do not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off.
  • Hold T-handle of removal tool to prevent it from turning, and run nut down against ev...

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Disc Brakes -> Adjustments -> Explorer -> F-Super Duty, Rear -> Parking Brake -> Rear Disc -> Transmission Mounted
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Parking Brake

Explorer
Rear Disc
  • Remove rear disc brake rotor as outlined in "Rotor, Replace".
  • Using tool No. D81L-1103-A or equivalent, brake adjustment gauge or equivalent, measure inside diameter of parking brake drum, Fig. .
  • Using parking brake adjuster screw, adjust parking brake shoe to .020 inch (.508 mm) less than drum measurement, Fig. .
  • Reverse procedure to install.
Transmission Mounted
F-Super Duty, Rear
  • Place transmission in neutral position and release parking brake, t...

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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...

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

CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1996 Ford Aerostar 4.0 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 ...

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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...

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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Trucks -> Check Fuel Cap Lamp ->
Vehicle: 1996 Ford Aerostar 3.0 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...

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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 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+.

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

Components on diagram:
  • Warning Chime Module
  • Data Link Connector
  • Rear Anti-Lock Brake System Module
  • Sliding Door Ajar Relay
  • Ignition Switch
  • Fuel Filter Diagram for 1996 Ford Aerostar  4.0 V6 GASFuel Filter Diagram for 1996 Ford Aerostar 4.0 V6 GAS

    Components on diagram:
  • Fuel Filter
  • 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:
  • Rear Anti-Lock Brake System (RABS) Module
  • PSOM Module
  • Instrument Cluster
  • Differential Speed Sensor (DSS)
  • Speed Control Amplifier
  • 1996 Ford Aerostar  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Main Light Switch
  • Engine Compartment Lamp
  • Engine Compartment Lamp Mercury Switch
  • LH/RH License Lamp
  • 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 details1995 Ford Aerostar Lift Support, 17 in. compressed length; 24.38 in. extended length; 7.38 in. travel; Includes installation instructions; Made of steel body pressure cylinder and nitro-carbonized rod for exceptional corrosion resistance and durability; Features plastic rod guide to reduce potential rod abrasion, main seal to provide positive closure for high pressure gas, and stop collar and limiting groove to assure precise extended length; High strength piston assembly with leak-proof seal helps prevent fluid leakage around the piston to allow fluid to pass efficiently through the piston valving components thus providing controlled lift and consistent performance; Exact replacement for worn out original unit..

    Source: Auto Body Parts Store

    $20.49

    Click here to view more details1995 Ford Aerostar Neutral Safety Switch, M12 x 1 NPT thread size; Pin type; 5-prong male terminal; A high quality, direct fit OE replacement neutral safety switch; With 2 years limited Trustbuilt warranty..

    Source: Auto Body Parts Store

    $64.27

    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; Silver, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    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 details1994 Ford Aerostar Used A/C Compressor, 4.0, AUTO, AWD integral AC, Very Good.

    Source: Used Auto Parts Store

    $113.00

    Click here to view more details1996 Ford Aerostar Used Fan Blade, 6-183 (3.0L), Very Good.

    Source: Used Auto Parts Store

    $64.00
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