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1994 Ford Aerostar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1994 Ford Aerostar AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> PRECAUTIONS
Vehicle: 1994 Ford Aerostar 3.0 V6 GAS
Refer to and for ai...
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BRAKE SERVICE PROCEDURES FOR 1994 Ford Aerostar AUTOMOBILES
Power Brake Units -> Bendix Vacuum Brake Booster -> Adjustments -> Bronco, E-Series & F-Series -> Pushrod -> Windstar
Vehicle: 1994 Ford Aerostar 3.0 V6 GAS
Pushrod
Bronco, E-Series & F-Series
To check adjustment of pushrod, fabricate a gauge and position it against the master cylinder mounting surface as shown in Fig. . Adjust pushrod screw by turning it until the end just touches inner edge of slot in gauge.
Windstar
- Without disconnecting brake tubes...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1994 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: 1994 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 1994 Ford Aerostar AUTOMOBILES
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1994 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 ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1994 Ford Aerostar AUTOMOBILES
Alternator, Replace
Vehicle: 1994 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 1994 Ford Aerostar AUTOMOBILES
Ford Motor Co. Trucks -> Rear Load Leveling (CHECK SUSP) ->
Vehicle: 1994 Ford Aerostar 4.0 V6 GAS
The CHECK SUSP indicator lights when there is a fault of the rear load ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1994 Ford Aerostar AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1994 Ford Aerostar 4.0 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 1994 Ford Aerostar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1994 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 1994 Ford Aerostar AUTOMOBILES
Component location diagrams for most 1994 Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
Body Components Diagram for 1994 Ford Aerostar 4.0 V6 GAS Components on diagram: |
Body Components Diagram for 1994 Ford Aerostar 4.0 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1994 Ford Aerostar AUTOMOBILES
OEM drawn wiring diagrams for most 1994 Ford Aerostar cars and light trucks sold in the U.S.
1994 Ford Aerostar 4.0 V6 GAS Wiring Diagram Components on diagram: |
1994 Ford Aerostar 3.0 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1994 Ford Aerostar AUTOMOBILES
OEM TSB listings for most 1994 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: 1994 Ford Aerostar 3.0 V6 GAS Auto Systems: |
Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 1994 Ford Aerostar 3.0 V6 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 1994 Ford Aerostar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1994 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 1994 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 1994 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 1994 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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