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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!

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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 -> Instrument Panel, Replace -> 1996 -> Econoline -> Expedition & 1997 F-Series -> Explorer & Mountaineer -> Ranger -> Windstar
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Econoline
    1996
    • Disconnect wiring on instrument panel in engine compartment by loosening bolt in center of connector.
    • Remove right and left inside windshield molding, Fig. .
    • Remove engine cover.
    • Remove left and center snap in molding on each side of steering column.
    • Remove attaching screws and bolts from steering column opening reinforcement.
    • Remove steering column shrouds, then disconnect electrical connectors at bottom of steering column.
    • Loosen retaining bolt and disconnect ignition switch connector from steerin...

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

    BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Power Brake Units -> Bendix Vacuum Brake Booster -> Description
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units. These are vacuum suspended units that use vacuum and atmospheric pressure for their power.

    On gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel engine vehicles, vacuum is supplied through a vacuum pump.

    The three basic elements of the booster are the vacuum power chamber, mechanically actuated booster check va...

    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 Shutoff Switch Location -> 1986-97 Aerostar
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    The inertia switch is located ...

    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, Replace -> Front -> Install -> Rear -> Remove
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Front

    Remove
    • Mark driveshaft and axle companion flanges as well as driveshaft boot and transfer case front output, so driveshaft can be reinstalled in same position.
    • Release Oetiker low-profile clamp on driveshaft boot with boot clamp pliers tool No. D87P-1090-A or equivalent and free boot from transfer case.
    • Remove axle snubber from beneath pinion.
    • Remove four bolts retaining front driveshaft to front axle companion flange.
    • Remove nuts from transmission mount studs in front crossmember.
    • Raise (jack) transfer case so transmission mount studs are almost out of front crossmember.
    • Slid...

    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 -> Low Oil Level Warning Indicator ->
    Vehicle: 1996 Ford Aerostar 3.0 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 4.0 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+.

    Instrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar  3.0 V6 GASInstrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar 3.0 V6 GAS

    Components on diagram:
  • Transmission Control Switch
  • Inertia Fuel Shut-Off Switch
  • Wiper Control Module
  • Radio
  • Instrument Cluster
  • 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:
  • Transmission Control Switch (TCS)
  • PCM Power Relay
  • Mass Air Flow (MAF) Sensor
  • Transmission Control Indicator Lamp (TCIL)
  • Powertrain Control Module (PCM)
  • 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 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 1993 Ford Aerostar Alternator1993 Ford Aerostar Alternator, 95 amps output, 12 V, internally regulated, clockwise rotation, 3 o'clock position; Includes pulley; A high quality, direct fit OE replacement alternator; No core required..

    Source: Auto Body Parts Store

    $116.67

    Click here to view more details about 1997 Ford Aerostar Door Mirror, Driver Side1997 Ford Aerostar Door Mirror, Driver Side, DOOR MIRROR, LH, MANUAL , , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $64.49

    Click here to view more details1986 Ford Aerostar L4, 2.3 L, 140 CID Rebuilt Engine, FI, Ranger, flat bottom intake ports, heart shaped combustion chamber, flat rear main cap, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,316.00

    Click here to view more details1994 Ford Aerostar Used Headlight, Passenger Side, CHROME, LT. PITTS, NEEDS BUFF, Very Good.

    Source: Used Auto Parts Store

    $93.00

    Click here to view more details1996 Ford Aerostar Used Condenser Assembly, 4.0, COL, RWD (integral AC), Very Good.

    Source: Used Auto Parts Store

    $141.00
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