1997 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...

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.

A ROUGH IDLE, STALLING AT AN IDLE AND/OR DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0174, AND/OR P1151 MAY BE STORED IN...

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

ENGINEERING IS INVESTIGATING CONCERNS OF THE REAR ABS LIGHT COMING ON WHEN THE IGNITION IS IN THE ON POSITION.

ENGINES MAY EXHIBIT A DRIVEABILITY CONCERN DESCRIBED AS A SURGE/BUCK/JERK OR HESITATION.

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

ENGINEERING IS INVESTIGATING CONDITIONS THAT CAUSE THE ABS LIGHT (RABS) TO ILLUMINATE.

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.

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

BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK.

SOME 4.0L ENGINES WITH BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK.

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

COLD ENGINE KNOCK/TICK NOISE.

COLD ENGINE KNOCK/TICK NOISE.

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

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.

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.

UPDATE INFORMATION FOR 1997 4R44E AND 5R55E TRANSMISSIONS - THERE ARE TWO (2) DIFFERENT SIZE DIRECT CLUTCH STEEL PLATES...

SERVICING TIP - TRANSMISSION - THERE ARE TWO DIFFERENT SIZE DIRECT CLUTCH STEEL PLATES WHEN SERVICING 4R44E OR 5R55E TRANSMISSIONS.

FLUID- TRANSMISSION FLUID USAGE CHARTS.

THE VEHICLES WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSITION.

THE VEHICLE WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSTION.

AS OF 1/7/97 THE AUTOMATIC SHIFT LOCK FEATURE TAG THAT WAS AFFIXED AROUND THE GEAR SELECTOR, HAS BEEN DISCONTINUED FOR PRODUTION.

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

FLUID - NEW MERCON V REQUIRED - TRANSMISSION - 4R44E - DESCRIPTION OF FEATURES AND MAJOR COMPONENTS.

TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP.

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP.

SOME VEHICLES EQUIPPED W/ AN AX4S TRANSAXLE MAY HAVE BEEN SHIPPED W/ A LOW TRANSAXLE FLUID LEVEL.

LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK.

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS.

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.

BATTERY- DISCHARGED- VEHICLES BUILT THROUGH 2/14/97.

DISCHARGED BATTERIES MAY BE CAUSED BY INTERMITTENT ELECTRICAL DRAW DIFFICULT TO DUPLICATE.

DISCHARGED BATTERIES ON 97 AEROSTARS MAY BE CAUSED BY AN INTERMITTENT ELECTRICAL DRAW THAT MAY BE DIFFICULT T DUPLICATE.

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.

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES.

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.

ISSUES REGAREDING DIAGNOSTIC TROUBLE CODES ( DTCS ) P0705, P0708, P1704, AND / OR P1705 MAY BE STORED IN MEMORY.

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

CONCERNS WITH A WHISTLING OR HISSING NOISE FROM THE MAIN CONTROL AREA OCCURING WHILE IDLING IN DRIVE AND / OR REVERSE ON SOME VEHICLES.

SOME DIFFICULTY IN MATCHING THE TEXTURE OF THE OEM ANTI-CHIP STONE ABRASION MATERIAL TO RPAIR MATERIALS WHEN SERVICING.

REPAIRS TO VINYL COVERED SURFACES.

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.

SOME VINYL COVERED ITEMS SUCH AS DASH PANELS, DOOR TRIM PANELS, CONSOLES, ETC., MAY EXHIBIT A SMALL DENT, SCUFF,...

SERVICE TIPS FOR SURFACE DEFECT REMOVAL WITHOUT REPAINTING.

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.

WINDSHIELD AND INTERIOR GLASS - FOG/FILM.

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

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.

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.

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.

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.

LOCKS FAILED. YD

INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED COMPONENT.

INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED PARTS.

INFORMATION REGARDING PUMP ALIGNMENT TOOLS.

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE.

SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE.

FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS.

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.