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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

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

    [[table data]]

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

    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 4.0 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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    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 Filter Replacement -> Except Diesel Engines & Villager
    Vehicle: 1996 Ford Aerostar 3.0 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 has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.

    On model...

    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 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 ...

    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 3.0 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 -> Check Engine Lamp -> 1993-97 -> Continuous Memory -> EEC -> EEC IV -> EEC V -> Except Malfunction Indicator Lamp (MIL) -> Keep Alive Memory (KAM) -> Keep Alive Memory (KAM) Reset & PCM Reset Less Electronic Tester -> Malfunction Indicator Light -> PCM Reset Using Generic Scan Tool
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    EEC

    Except Malfunction Indicator Lamp (MIL)

    When using NGS tool No. 007-00500, or equivalent, select Diagnostic Test Mode Results, then press CLEAR or disconnect battery ground cable. Codes will be erased from back-up memory after 24 hours.

    Malfunction Indicator Light
    • Activate diagnostic test mode.
    • Disconnect diagnostic connector.
    • Jump BL/W and GY/BL wires using suitable jumper wire.
    • Wait about two seconds.
    • Remove jumper wire and reconnect diagnostic connector.
    • MIL will stay on, and codes will be erased.

    EEC IV

    Continuous Memory

    This lamp should light when the ignition is turned On. After the engin...

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

    RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Radiator, Replace
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    • Drain cooling system into a suitable container as follows:
      • Remove radiator cap and attach 3/8 inch inside diameter hose to draincock nipple, located at lower rear corner of radiator tank.
    • Remove rubber radiator overflow hose from radiator and store it out of way.
    • Remove two upper fan shroud or finger guard screws, then lift fan shroud out of lower clips and drape on fan blade.
    • Loosen upper and lower hose clamps at radiator, then remove upper radiator hose and lower radiator hose from radiator connectors.
    • On models equipped with automatic transmission,proceed as follows;
      • Disconnect a...

    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 4.0 V6 GAS

    • Raise tensioner by turning counterclockwise, then remove belt.
    • Install new be...

    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/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  3.0 V6 GASBody Connector & Component Locations w/Rear Door & Hatch Connector Locations Diagram for 1996 Ford Aerostar 3.0 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  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Left Rear Seat Speaker
  • Left Front Speaker
  • Right Rear Seat Speaker
  • Right Front Speaker
  • 1996 Ford Aerostar  4.0 V6 GAS Wiring Diagram1996 Ford Aerostar 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Transmission Range (TR) Sensor
  • Starter Motor/Solenoid
  • Battery
  • Starter Relay
  • Ignition 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 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 1997 Ford Aerostar Bumper Cover, Front1997 Ford Aerostar Bumper Cover, Front, With holes for air, license plate, and molding; A high quality, OE replacement bumper cover; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $144.48

    Click here to view more details1995 Ford Aerostar Taillight Driver Side, Driver Side Tail Light Lens And Housing; For Use With Or Without Rear Wiper, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $59.45

    Click here to view more details about 1994 Ford Aerostar V6, 4 L, 245 CID Rebuilt Engine1994 Ford Aerostar V6, 4 L, 245 CID Rebuilt Engine, Aerostar 90-94, Explorer 90-92, Ranger 90-92. If for 90-94 Aerostar, 90-92 Explorer/Ranger with manual trans or 93-94 Explorer/Ranger use FOR-244RLB-1. Supplied with new head casting., Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $2,105.00

    Click here to view more details1986 Ford Aerostar Used A/C Compressor, 5.0, AUTO, 4X4 hang-on AC, Very Good.

    Source: Used Auto Parts Store

    $125.00

    Click here to view more details1996 Ford Aerostar Used Air Flow Meter/Sensor, 6-232 (3.8L), Very Good.

    Source: Used Auto Parts Store

    $65.00
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