1996 Ford Aerostar TSBs

SOME VEHICLES BUILT PRIOR TO 9/15/2001 MAY EXHIBIT LOW LINE PRESSURE READINGS WHILE IN DRIVE, NO 2ND GEAR, NO 3RD GEAR,...

SOME VEHICLES MAY EXHIBIT A NO 1-2 UPSHIFT, NO 2-3 UPSHIFT, A NO ENGINE BRAKING CONDITION IN MANUAL 1 OR DIAGNOSTIC...

SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE,...

ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE.

SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A...

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.

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

INFORMATION REGARDING CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART.

SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR ALIGNMENT TOOL FOR VEHICLES WITH VARIOUS ENGINE SIZES.

DURING EXTREME COLD AMBIENT TEMPERATURES AND UNDER CERTAIN DRIVING CONDITIONS, MOISTURE IN THE CRANKCASE MAY ENTER THE...

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

FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS.

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR.

FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS.

VEHICLES EXHIBITING A "SQUEAKING" OR "CHIRPING" FROM THE BLOWER MOTOR AT LOW BLOWER MOTOR SPEEDS.

3.0L VEHICLES SETTING MISFIRE CODES P0300-P0306 SHOULD BE SERVICED USING NORMAL DIAGNOSTICS.

THE AIR OPERATED COOLING FAN MAYU RUN CONTINUOUSLY IF THE ENGINE ECM FAN CONTROL PARAMETERS ARE SET INCORRECTLY.

BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS.

FUEL INJECTION PUMP- BOSCH- SERVICE INFORMATION FOR FD1060/1460 DIESEL ENGINES.

FD 1460 ENGINES - NON-FUNCTIONING AIR INTAKE HEATERS - ENSURE THAT THE DIAGNOSTIC SWITCH IS IN OFF POSITION.

MISFIRE CODES P0300-P0306.

4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPNIED WITH A THUMPING NOISE OR FEEL...

4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPANIED WITH A THUMPING NOISE OR...

MISFIRE CODES P0300-P0306- REPROGRAMMING PROCEDURES DO NOT APPLY TO AEROSTAR3.0L CALIBRATIONS.

COLD ENGINE KNOCK/TICK NOISE.

ENGINE - 4.0L - TORQUE-TO-YIELD (TTY) CRANKSHAFT DAMPER BOLT.

ENGINE - 4.0L - NEW TORQUE-TO-YIELD CONNECTING ROD FASTENERS.

LONG CRANK - STICKING IDLE AIR CONTROL (IAC) VALVE - VEHICLES BUILT FROM 11/1/94 THROUGH 3/30/96 -STALL - AFTER STARTING...

COLD ENGINE KNOCK/TICK NOISE.

CHECK ENGINE LIGHT, CODE P030X, WITH NO DRIVEABILITY COMPLAINT.

2.5L DURATEC ENGINE EXCHANGES NO LONGER INCLUDE FRONT END ACCESSORY DRIVE COMPONENT, OIL LEVEL INDICATOR, WATER PUMP...

LACK OF COOLING DUE TO COMPLETE LOSS OF CHARGE.

ON TRANSMISSIONS BUILT BEFORE 6/20/95 (FIG 1) AN EXTENDED SHIFT AND A HIGHER ENGINE RPM THAN EXPECTED AND/OR NO SHIFT...

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

INCORRECTLY INSTALLED GEAR DRIVEN CAMSHAFT POSITION (CMP) SENSOR SYNCHRONIZER ASSEMBLIES CAUSING SURGE, LOST OF POWER,...

LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT), SLIPPING SHIFTS AND / OR DELAYED ENGAGEMENTS WITH POSSIBLE...

BRAKE SHIFT INTERLOCK.*JB

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS.

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

WHEN REPLACING AN INTERNAL WIRING HARNESS ON 4R44E/4R55E TRANSMISSIONS BUILT BEFORE 11/30/95 WITH A NEW HARNESS, THE FLUID PAN MUST BE REPLACED ALSO.

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP.

CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK.

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART.

FLUID- TRANSMISSION FLUID USAGE CHARTS.

TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP.

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP.

LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK.

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS.

THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS.

INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT.

SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT.

AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT.

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE.

SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS.

HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE.

BRAKES - BRAKE SERVICE - SERVICE TIPS.

BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP.

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE...

INFORMATION ON REPLACING AND / OR REPAIRING MALFUNCTIONING (DOOR, IGNITION AND DECKLID) LOCKS.

SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES.

INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS).

MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP.

VEHICLE ELECTRICAL SYSTEM, SEVERAL MEGAFUSES ARE USED.

POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP.

MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP.

WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS.

FOR CONCERNS OF STALLING, REFLASH PCM W/ 1996 CALIBRATION (R11 LEVEL).

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

INFORMATION REGARDING TRANSFER CASE REAR HOUSING AND DRIVESHAFT REPLACEMENT.

INFORMATION ON SERVICING OIL PAN GASKET LEAKS.

INFORMATION REGARDING REPLACEMENT AND / OR REPAIRS ON ANY LOCK COMPONENT.

CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES.

RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES.

EXPERIENCING A "THUMPING" NOISE OR TEMPEATURE GAUGE FLUCTATION WITH SOME VEHICLES.

AEROSTAR E4WD MODELS MAY EXPERIENCE FRONT AXLE LUBRICANT LEAKAGE FROM THE VENT TUBE UNDER SOME DRIVING CONDITIONS.

SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP.

SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED.

FRONT AND REAR BUMPERS MADE OF XENOY PLASTIC HAVE HAD THE CONDUCTIVE PRIMER REMOVED FROM SERVICE PARTS.

WINDSHIELD CRACKS. *TW

INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES.

SLIDING DOOR - DAMAGED OR MISADJUSTED LATCH MECHANISM.

WINDSHIELD AND INTERIOR GLASS - FOG/FILM.

1996-1997 AEROSTAR INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES.

EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP.

EXPERIENCING A " BUZZING " OR " RATTLING " NOISE FROM THE EXHAUST SYSTEM.

INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM.

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE.

DIAGNOSTIC INSTRUCTIONS FOR SERVICING EVAPORATIVE EMISSION PURGE FLOW SYSTEM.

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS.

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS.

AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL.

CONCERNS OF A/C GOING TO DEFROST MODE WHEN CLIMBING GRADES OR ACCELERATING ARE LIKELY CAUSED BY VACUUM LEAKS.

LOCKS FAILED. YD

INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED COMPONENT.

INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED PARTS.

INFORMATION FOR WHEN DIAGNOSING CONCERNS W/ FACTORY INSTALLED CELLULAR PHONES.

SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE.

FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS.

RECALL 96E58 - LOW VOLUME RECALL - 229 VEHICLES INVOLVED - REISSUE OF RECALL DOCUMENTATION TO DEALERS.

INFORMATION REGARDING PUMP ALIGNMENT TOOLS.

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE.

EXPERIENCING A RAPPING OR CLANGING NOISE WHEN THE STEERING WHEEL IS TURNED RAPIDLY OR WHEN TURNING ON A BUMPY ROAD SURFACE.

EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO.

AIR CONDITIONING- R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE O-RING SPRING LOCK COUPLERS- SERVICE TIP.