1990 Ford Aerostar Service and Repair Manual

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Factory-Grade Data

The 1990 Ford Aerostar service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • XL Plus Mini Passenger Van 2-Door
  • XLT Plus Mini Passenger Van 2-Door
  • Base Mini Passenger Van 2-Door
  • Base Mini Cargo Van 2-Door
  • Base Extended Passenger Van 2-Door
  • Eddie Bauer Mini Passenger Van 2-Door
  • XL Mini Passenger Van 2-Door
  • XLT Mini Passenger Van 2-Door

Engines covered

  • 4.0L 245Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.0L 2986CC 182Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1990 Ford Aerostar Recalls & Complaints

NHTSA #89V22300011/12/1989Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

INABILITY TO MAINTAIN PRESSURE IN THE SECONDARY SYSTEM OF THE MASTER CYLINDER (CONTROLS BRAKING OF REAR WHEELS) COULD INCREASE BRAKE PEDAL TRAVEL AND REDUCE BRAKE PERFORMANCE AT TE

Consequence

THIS WOULD CAUSE REDUCED BRAKING EFFECTIVENESS ANDINCREASED STOPPING DISTANCE THAT COULD R

Remedy

INSTALL NEW DESIGN MASTER CYLINDER INCORPORATING A REDESIGNED SEAL.

NHTSA #98V19000011/08/1998Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

VEHICLE DESCRIPTION: MINI VANS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA (10 SOUTHERN COUNTIES OF LOS ANGELES, ORANG

Consequence

IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.

Remedy

DEALERS WILL REPLACE THE FUEL TANK, REGARDLESS OF MILEAGE, THROUGH MARCH 31, 2002. THIS C

TSB #627752

SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT

TSB #623944

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

TSB #623988

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

TSB #622665

ON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA AFTER AN ENGINE OIL PAN GASKET REPAIR HAS BEEN PERFORMED. *TT

TSB #616522

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

TSB #608431

INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT

TSB #615140

OWNER NOTIFICATION PROGRAM INVOLVING THE FUEL TANK ON AFFECTED VEHICLES WHICH CAN DEVELOP CRACKS AT THE UPPER PORTION OF THE TANK AS A RESULT OF EXTENDED EXPOSURE TO VERY HIGH AMBIENT TEMPERATURES. *TT

TSB #6091931

SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT

Showing the 8 most recent of 46 technical service bulletins on file with NHTSA.

20040721Component: VEHICLE SPEED CONTROLCrash reported3 injured

UPON STARTING THE VEHICLE, IT ACCELERATED AT A HIGH SPEED AND CRASHED INTO A BUILDING. THE DRIVER'S FOOT WAS ON THE BRAKE PEDAL WHEN SUDDEN ACCELERATION OCCURRED. THE VEHICLE WA

20040721Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported3 injured

UPON STARTING THE VEHICLE, IT ACCELERATED AT A HIGH SPEED AND CRASHED INTO A BUILDING. THE DRIVER'S FOOT WAS ON THE BRAKE PEDAL WHEN SUDDEN ACCELERATION OCCURRED. THE VEHICLE WA

19950719Component: VEHICLE SPEED CONTROLCrash reported3 injured

VEHICLE HAD SUDDEN ACCELERATION WITH NO WARNING. TT

19991105Component: VEHICLE SPEED CONTROL:LINKAGESCrash reported2 injured

WHILE DRIVING 25MPH THE VEHICLE ACCELERATED SUDDENLY, RESULTING IN A COLLISION THAT CAUSED MINOR INJURIES. MANUFACTURER WILL BE NOTIFIED. *AK

Showing the 4 most serious of 254 complaints filed with NHTSA.

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