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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 -> VACUUM MOTOR, REPLACE -> AEROSTAR -> BRONCO & F SERIES -> ECONOLINE -> EXPLORER & RANGER -> Mix Door -> Outside Recirculating Door -> Panel/Defrost Door
Vehicle: 1992 Ford Aerostar 4.0 V6 GAS
ECONOLINE
Outside Recirculating Door
Refer to Figs. and , for vacuum motor replacement and proceed as follows:
- Remove two screws attaching motor to evaporator housing.
- Disconnect vacuum hose from outside-recirculating vacuum motor, then remove motor and bracket.
- Lift vacuum motor until arm is out of channel which retains arm to pin. Slide arm off pin on cam, then remove motor.
- Reverse procedure to install.
BRONCO & F SERIES
Outside Recirculating Door
- Disconnect blower motor electrical connector, th...
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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 -> Aerostar, Bronco, Explorer, E-150, F-150 & Ranger -> Precautions
Vehicle: 1996 Ford Aerostar 4.0 V6 GAS
When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, precautions should be taken to minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.
- Wear a suitable respirator approved fo...
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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 Shutoff Switch Location -> 1986-97 Aerostar
Vehicle: 1997 Ford Aerostar 4.0 V6 GAS
The inertia switch is located ...
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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+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Double Cardan -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1993 Ford Aerostar 3.0 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 Ford Aerostar AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Ford Aerostar cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1991 Ford Aerostar 4.0 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly, if required.
- Disconnect wire harness connectors from voltage regulator.
- Remove accessory drive belt.
- Remove alternator mounting bolts, then alternator from vehi...
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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 -> Fuel Reset ->
Vehicle: 1990 Ford Aerostar 3.0 V6 GAS
The FUEL RESET indicator is grounded through the inertia switch whenever vehicle is in a high force situation. The Inertia F...
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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: 1990 Ford Aerostar 4.0 V6 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp at radiator outlet and remove hose.
- Reposition hose clamp at engine and remove hose.
- Remove hose from vehicle.
- Reverse procedure to install.
Upper
- Drain cooling syste...
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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: 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 Ford Aerostar AUTOMOBILES
Component location diagrams for most Ford Aerostar cars and light trucks sold in the U.S. from 1990+.
 Front Of Engine Diagram for 1989 Ford Aerostar 3.0 V6 GASComponents on diagram: |
 Body Components Diagram for 1991 Ford Aerostar 4.0 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.
 1986 Ford Aerostar 2.8 V6 GAS Wiring DiagramComponents on diagram: |
 1996 Ford Aerostar 3.0 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: TOOL MODIFICATION - ROTUNDA "GAS-CHEK" KIT Vehicle: 1987 Ford Aerostar 2.3 L4 GAS Auto Systems: |
|
Document: TRANSMISSION FLUID USAGE CHARTS Vehicle: 1993 Ford Aerostar 4.0 V6 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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