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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!
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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 -> Compressor, Replace -> 4.2L Engine -> 4.6L, 5.4L & 6.8L Engines -> 4.9L Engine -> 5.0L, 5.8L & 7.5L Engines -> 7.3L Engine -> Aerostar, Explorer, Mountaineer & Ranger -> Bronco & 1996 Econoline & F-Series -> Expedition & 1997 Econoline & F-Series -> Villager -> Windstar
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

Bronco & 1996 Econoline & F-Series
4.9L Engine
  • Recover refrigerant as outlined under .
  • Disconnect wire connector from clutch field coil connector.
  • Remove retaining bolts from compressor manifolds.
  • Remove refrigerant lines. Plug lines and compressor ports to prevent dirt and moisture contamination.
  • Remove hex head screw attaching compressor adjusting arm to mounting bracket.
  • Remove four front and rear braces to mounting bracket support attaching screws.
  • Remove compressor with front and rear braces attached, from vehicle,...

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Aerostar AUTOMOBILES

Disc Brakes -> Brake System Bleed
Vehicle: 1996 Ford Aerostar 3.0 V6 GAS

Bleed primary and secondary hydraulic brake systems separately, bleeding the longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from the hydraulic system.

  • Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid.
  • Depress brake pedal slowly forcing air trapped in master cylinder out at fitting.
  • Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to en...

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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

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Double Cardan -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

Single Cardan, Slip Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

  • Index-mark the shaft components.
  • Remove and discard all four snap rings.
  • Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
  • If necessary, use a pair of pliers to remove a bearing cup t...

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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 -> Electronic Throttle Control ->
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS

Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...

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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 4.0 V6 GAS

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

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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
  • Instrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar  4.0 V6 GASInstrument Panel Connector & Component Locations w/Instrument Cluster Connector Locations Diagram for 1996 Ford Aerostar 4.0 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  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Illumination
  • Rear Window Defrost Grid
  • Rear Window Defrost Control
  • 1996 Ford Aerostar  3.0 V6 GAS Wiring Diagram1996 Ford Aerostar 3.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Warning Chime Module
  • Main Light Switch
  • LH Courtesy Lamp 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 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 details about 1997 Ford Aerostar Wiper Blade, Front, Driver Or Passenger Side, Rear1997 Ford Aerostar Wiper Blade, Front, Driver Or Passenger Side, Rear, 22 in. length, Includes universal plastic adapters and easy to follow installation instructions; This new generation flat blade provides improved wiping capabilities in rain and freezing weather, long lasting durability, an easy to service design using a rubber insert that requires no special tools or high cost items to replace, and a clean appearance from inside the vehicle with the wiper profile neatly conforming to the base of the windshield; Backed by 1-year, unlimited-mileage warranty..

    Source: Auto Body Parts Store

    $5.00

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

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    Click here to view more details about 1986 Ford Aerostar V6, 2.8 L, 171 CID Rebuilt Engine1986 Ford Aerostar V6, 2.8 L, 171 CID Rebuilt Engine, Ranger, Aerostar, Bronco II, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,487.00

    Click here to view more details1986 Ford Aerostar Used Suspension Cross Member/Subframe, 3.0, AUTO, FWD FRONT; RWD, LT SURFACE RUST, Very Good.

    Source: Used Auto Parts Store

    $260.00

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

    Source: Used Auto Parts Store

    $77.00
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