1996 Ford Aerostar Service and Repair Manual

This factory service and repair manual for the 1996 Ford Aerostar is the reference for a van offered with the 4.0L OHV V6 or the 3.0L OHV V6, both naturally aspirated gasoline engines, in the two-door mini passenger van, the two-door extended passenger van and the two-door mini cargo van. There are four trims: Base, XLT, XLT Plus and XLT Sport. The procedures, specifications, torque values, wiring diagrams and diagnostics cover both engines and the systems around them, including the brakes and wheels that draw most of this year's owner complaints.

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

Known issues on the 1996 Aerostar. Six recalls are on federal record for this model year. One concerns the driver door latch, which may open under a side load when closed only to its secondary latched position; another is a certification label with incorrect rear tire inflation pressures that could cause premature tire wear; a third is the ignition switch accessory feed circuit that can short and overheat. Owners have filed 109 complaints with NHTSA, and they cluster on the wheels first, then the service brakes and the power train. Wheel and brake procedures, torque values and driveline specifications in this manual cover that ground.