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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!
    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 -> Electric Actuators, Replace -> 1997 Econoline -> A/C Electronic Door -> Expedition & 1997 F-Series -> Panel/Floor/Defrost Door -> Recirculation/Air Door -> Temperature Blend/Panel Bypass Door -> Villager -> Windstar
    Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

    Expedition & 1997 F-Series
    • Remove floor duct panel, then the righthand instrument panel brace.
    • Remove lefthand instrument panel lower nut and position brace aside.
    • Remove two floor duct attaching screws and the duct.
    • Remove three actuator screws and disconnect electrical connector.
    • Release actuator shaft by pulling downward, then remove actuator.
    • Reverse procedure to install.
    Villager
    Recirculation/Air Door
    • Remove four console compartment plastic screws or the C/D changer cover plastic screws, if equipped.
    • ...

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

    BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Drum Brakes -> Aerostar, Bronco, Explorer, E-150, F-150 & Ranger -> Inspection -> Adjuster Mechanism -> Backing Plate -> Brake Drums -> Brake Linings & Springs -> Parking Brake Cable
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    Brake Drums

    Any time brake drums are removed for brake service, braking surface diameter should be checked with a suitable micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If braking surface diameter exceeds specifications, the drum must be replaced. If braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced.

    Minor scores should be removed with sa...

    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

    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 -> Severity Indicator ->
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    This indicator will display the severity color of RED when low oil pressure, charging system malfunction, engine coolant overheating or door ajar problems ar...

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

    RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

    Heater Hose, Replace -> Inlet -> Outlet
    Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

    Inlet

    • Drain cooling system into a suitable container.
    • Reposition heater core inlet hose clamp at intake manifold.
    • Remove hose from intake manifold.
    • Reposition heater hose inlet clamp at heater core.
    • Remove heater inlet hose from heater core.
    • Remove hose from vehicle.
    • Reverse procedure to insta...

    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  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 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  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Master Window Door Lock Switch
  • RH Window Door Lock 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 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 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 Parking Lamp Assembly, Passenger Side1997 Ford Aerostar Parking Lamp Assembly, Passenger Side, PARKING LAMP ASSEMBLY, RH, IN FENDER , , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $24.45

    Click here to view more details1989 Ford Aerostar V6, 3 L, 182 CID Rebuilt Engine, RWD, 86-88Aerostar & Ranger, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,543.00

    Click here to view more details1997 Ford Aerostar Used Air Flow Meter/Sensor, 2.5, AUTO, 4X2, Very Good.

    Source: Used Auto Parts Store

    $77.00

    Click here to view more details1992 Ford Aerostar Used Windshield Glass, R., Very Good.

    Source: Used Auto Parts Store

    $73.00
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