1997 Ford Aerostar Service and Repair Manual

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Factory-Grade Data

1997 Ford Aerostar service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • XLT Plus Mini Passenger Van 2-Door
  • XLT Extended Passenger Van 2-Door
  • XLT Plus Extended Passenger Van 2-Door
  • Base Mini Cargo Van 2-Door
  • XLT Mini Passenger Van 2-Door
  • XLT Sport 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

1997 Ford Aerostar Recalls & Complaints

NHTSA #06E02200013/03/2006Component: SERVICE BRAKES, HYDRAULIC

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE

Consequence

LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPP

Remedy

AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE

TSB #10014086

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

TSB #10008580

LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ

TSB #10008304

ENGINE-GEAR DRIVEN SYNCHRONIZERS-INCORRECT INSTALLATION-CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION. *MJ

TSB #10003748

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT

TSB #10000592

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

TSB #637922

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

TSB #637755

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

TSB #635998

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 107 technical service bulletins on file with NHTSA.

20010803Component: AIR BAGS:FRONTALCrash reported1 injured

VEHICLE WAS SLOWING DOWN GOING 35-45MPH IN THE RIGHT SLOW LANE. WHEN BRAKES WERE APPLIED, VEHICLE PICKED UP MORE SPEED, CAUSING CONSUMER TO LOSE CONTROL. VEHICLE RAN INTO ONE

20011217Component: AIR BAGS:FRONTALCrash reported

VEHICLE WAS IN A HEAD-ON COLLISION AND NEITHER OF THE AIR BAGS DEPLOYED. PLEASE PROVIDE MORE INFORMATION.*AK

20000626Component: VEHICLE SPEED CONTROL:LINKAGESCrash reported

CONSUMER WAS TURNING INTO A DRIVEWAY OFF OF A SMALL STREET, APPLIED BRAKES, AND THE VEHICLE SUDDENLY TOOK OFF ON ITS OWN. RPMS WENT UP, AND THE REAR TIRES WERE SPINNING. VEHI

19990928Component: AIR BAGS:FRONTALCrash reported

CONSUMER WAS DRIVING ON THE HIGHWAY AND WAS INVOLVED IN A COLLISION WHEN A DEER JUMPED IN FRONT OF TRUCK. AIRBAGS DIDN'T DEPLOY. *AK

Showing the 4 most serious of 83 complaints filed with NHTSA.

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