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Ford Aerostar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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!
A/C & HEATER SERVICE PROCEDURES FOR Ford Aerostar AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Ford Aerostar cars and light trucks from 1990+
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> THERMOSTAT, REPLACE -> 2.0L/4-122 & 2.3L/4-140 Engines -> 3.0L/V6-182 Engine -> 3.0L/V6-182 Engines -> 4.0L/V6-244 Engine -> 4.9L/6-300, 5.0L/V8-302, 5.7L/V8-351 & 7.5L/V8-460 Engines -> 7.3L/V8-445 Engine -> AEROSTAR -> BRONCO, ECONOLINE & F-SERIES -> EXPLORER & RANGER -> Installation -> Removal -> VILLAGER -> WINDSTAR
Vehicle: 1994 Ford Aerostar 4.0 V6 GAS
BRONCO, ECONOLINE & F-SERIES
4.9L/6-300, 5.0L/V8-302, 5.7L/V8-351 & 7.5L/V8-460 Engines
- Disconnect battery ground cable.
- Drain radiator.
- On models equipped with 4.9L/6-300 engine, remove coolant outlet attaching bolts, then pull elbow rearward to remove thermostat and gasket.
- On models equipped with 5.0L/V8-302, 5.8L/V8-351 and 7.5L/V8-460 engines, disconnect bypass hose at water pump and intake manifold, remove bypass tube, remove water outlet attaching bolts, bend upper radiator upward and remove thermostat and gasket.
- On all...
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BRAKE SERVICE PROCEDURES FOR Ford Aerostar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Ford Aerostar cars and light trucks from 1990+.
DRUM BRAKES, FORD -> Except E & F 250-350 & F-Super Duty -> BRAKE ADJUSTMENTS -> Aerostar -> Bronco II & Ranger -> PARKING BRAKE -> SERVICE BRAKE -> With Drums Installed -> With Drums Removed
Vehicle: 1990 Ford Aerostar 4.0 V6 GAS
SERVICE BRAKE
The rear brake shoes, Figs. and , adjust automatically when the vehicle is driven forward or reverse and the brakes are applied sharply several times. Manual adjustment is required only when brake shoes are replaced. When adjusting rear brakes, ensure that parking brake is properly adjusted and that equalizer is operating freely.
With Drums Removed
- With drums removed, clean areas where shoes contact backing plate, then apply suitable lubricant to these contact areas, ensuring that lubricant does not contaminate linings.
- Using suitable brake shoe adjusting gauge, ad...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Ford Aerostar AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Ford Aerostar cars and light trucks sold in the U.S. for 1980+.
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Except Diesel Engines & Villager
Vehicle: 1992 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 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...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Ford Aerostar AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Ford Aerostar cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1995 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 Ford Aerostar AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Ford Aerostar cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1993 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...
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MAINTENANCE LAMP RESET PROCEDURES FOR Ford Aerostar AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
Ford Motor Co. Trucks -> Severity Indicator ->
Vehicle: 1996 Ford Aerostar 3.0 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...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Ford Aerostar AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Ford Aerostar cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1997 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 Ford Aerostar AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
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 Ford Aerostar AUTOMOBILES
Component location diagrams for most Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Components w/Diode Location Diagram for 1995 Ford Aerostar 3.0 V6 GASComponents on diagram: |
 LH Fender Apron Diagram for 1989 Ford Aerostar 3.0 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Ford Aerostar AUTOMOBILES
OEM drawn wiring diagrams for most Ford Aerostar cars and light trucks sold in the U.S.
 1997 Ford Aerostar 4.0 V6 GAS Wiring DiagramComponents on diagram: |
 1992 Ford Aerostar 4.0 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Ford Aerostar AUTOMOBILES
OEM TSB listings for most Ford Aerostar cars and light trucks sold in the U.S. from 1985+.
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Document: A4LD - BAND ADJUSTMENT PROCEDURE (4.0L) - S/M REV Vehicle: 1990 Ford Aerostar 4.0 V6 GAS Auto Systems: |
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Document: TIRES - LOAD VS INFLATION - P-METRIC TIRES - WEAR Vehicle: 1986 Ford Aerostar 2.3 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Ford Aerostar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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
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