1996 Ford Aerostar Service and Repair Manual
Covers the 1996 Ford Aerostar passenger and cargo van in four trims, with two engines from 3.0 to 4.0 litres: naturally aspirated V6. Factory procedures, specifications and torque values for this model year.
NHTSA holds 109 owner complaints against the 1996 Aerostar, most often about wheels (22) and the brakes (17).
Engines covered
- 4.0L V6 (245 cu in) — OHV, naturally aspirated, gasoline
- 3.0L V6 (182 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door mini passenger van
- 2-door extended passenger van
- 2-door mini cargo van
Trims covered
- Base
- XLT
- XLT Plus
- XLT Sport
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE
LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ
ENGINE-GEAR DRIVEN SYNCHRONIZERS-INCORRECT INSTALLATION-CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION. *MJ
NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT
INCORRECTLY INSTALLED GEAR DRIVEN CAMSHAFT POSITION (CMP) SENSOR SYNCHRONIZER ASSEMBLIES CAUSING SURGE, LOST OF POWER, MALFUNCTION INDICATOR LAMP ON AND DIAGNOSTIC TROUBLE CODES P1336, P1309 AND P0340. *TT
SOME VEHICLES BUILT PRIOR TO 9/15/2001 MAY EXHIBIT LOW LINE PRESSURE READINGS WHILE IN DRIVE, NO 2ND GEAR, NO 3RD GEAR, NO ENGINE BRAKING IN MANUAL 1ST AND SLIPPING SHIFTS AND / OR DELAYED ENGAGEMENTS. *TT
SOME VEHICLES MAY EXHIBIT A NO 1-2 UPSHIFT, NO 2-3 UPSHIFT, A NO ENGINE BRAKING CONDITION IN MANUAL 1 OR DIAGNOSTIC TROUBLE CODE P0732 (GEAR 2 INCORRECT RATIO) OR P0733 (GEAR 3 INCORRECT RATIO). *TT
SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT
LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT), SLIPPING SHIFTS AND / OR DELAYED ENGAGEMENTS WITH POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 SET ON VEHICLES BUILT BEFORE 12/1/2001. *TT
Showing the 8 most recent of 104 technical service bulletins on file with NHTSA.
IN A MULTIPLE CAR PILE-UP, WITH SPEEDS BETWEEN 35 AND 50 MPH THE DRIVER'S AIRBAG IN OUR VAN (VEHICLE NUMBER #3 OF 4 INVOLVED) DID NOT DEPLOY. OUR VEHICLE WAS DAMAGED ACROSS THE E
VAN INVOLVED IN HEAD ON COLLISION WHILE SITTING STILL. SPEED FROM OTHER VEHICLE ESTIMATED AT 40 MPH. AIR BAG FAILED TO DEPLOY UPON COLLISION. IMPACT WAS TO EXTENT OF FRAME
Showing the 2 most serious of 109 complaints filed with NHTSA.
