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 -> Blower Motor, Replace -> 2.3L, 3.0L & 4.0L Engines -> 5.0L Engine -> Aerostar -> Auxiliary -> Bronco & 1996 F-Series -> Econoline -> Expedition & 1997 F-Series -> Explorer, Mountaineer & Ranger -> Front -> Rear -> Standard -> Villager -> Windstar
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Econoline
Standard
  • Remove battery and tray.
  • On models with A/C, move accumulator/drier.
  • On all models, disconnect electrical connector to blower motor, then remove blower motor housing tube.
  • Remove four blower motor attaching screws. To ease removal, rotate blower motor to align flat spot on mounting plate with the accumulator/drier.
  • Reverse procedure to install.
Auxiliary
  • Remove third, fourth and fifth bench seats, if equipped.
  • Remove left center bolster trim panel, left lower front trim panel, left re...

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Anti-lock Brakes -> 1993-96 Aerostar, E-Series, F-Series & Ranger (RABS) -> Diagnosis & Testing -> 1996 E-SERIES -> 1996 F-SERIES -> Accessing Diagnostic Trouble Codes -> AEROSTAR, RANGER & 1992-95 E-SERIES & F-SERIES -> Clearing Diagnostic Trouble Codes -> Diagnostic Procedures -> Diagnostic Trouble Code Interpretation -> Drive Tests -> Intermittent Diagnosis -> Pinpoint Tests -> Programmable Speedometer/Odometer Module (PSOM) Signal Verification -> Symptom Chart -> System Pre-Check
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Accessing Diagnostic Trouble Codes

  • Ensure ignition switch is in Run position with engine off.
  • Locate black RABS II diagnostic connector. Disconnect two halves of connector (one side has an orange/black wire attached to it).
  • Attach a jumper wire to the orange/black wire side of the connector. Momentarily ground the opposite end of jumper for 1-2 seconds.
  • The "REAR ABS" lamp should start flashing a diagnostic trouble code.

Diagnostic Trouble Code Interpretation

  • Diagnostic trouble codes consist of a number of short flashes and ends with one long flash. Count short and long flashes to o...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 1996 Ford Aerostar 4.0 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 ...

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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

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 -> Low Fuel Level Warning Lamp ->
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

When fuel level drops below a predetermined level, the CHECK GAUGE indicator should light. The CHECK GAUGE indicator shoul...

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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+.

Engine Compartment Components w/Diode Location Diagram for 1996 Ford Aerostar  4.0 V6 GASEngine Compartment Components w/Diode Location Diagram for 1996 Ford Aerostar 4.0 V6 GAS

Components on diagram:
  • Purge Flow Sensor
  • PCM Power Relay
  • Brake Fluid Level Switch
  • RABS Proportioning Valve Switch Assembly
  • Windshield Wiper Motor
  • Engine Connector & Component Locations (Top View) Diagram for 1996 Ford Aerostar  4.0 V6 GASEngine Connector & Component Locations (Top View) Diagram for 1996 Ford Aerostar 4.0 V6 GAS

    Components on diagram:
  • Rear Heated Oxygen Sensor
  • Throttle Position Sensor
  • Radio Noise Capacitor
  • Fuel Injector #1
  • Fuel Injector #5
  • 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:
  • Ignition Switch
  • PCM Power Relay
  • Radio Noise Capacitor
  • Ignition Coil
  • Powertrain Control Module
  • 1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Power Mirror Switch
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    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!

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    $69.50

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

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    $63.00

    Click here to view more details1995 Ford Aerostar Used Cylinder Head, 2FT4, 12/12 WAR, Z786144.

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    $434.00
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