1996 Ford Aerostar service bulletins & manufacturer communications
104 manufacturer communications are on file with NHTSA for the 1996 Ford Aerostar. TSBs are repair guidance for dealers — they are not recalls, and repairs are not automatically free.
Technical service bulletin 104
- 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…02138 · Technical service bulletin · Power Train · issued Nov 10, 2003
- New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt03148 · Technical service bulletin · Power Train · issued Jul 21, 2003
- Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj02221 · Technical service bulletin · Engine and Engine Cooling · issued Nov 11, 2002
- Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1…870197 · Technical service bulletin · Engine and Engine Cooling · issued Oct 22, 2002
- Lamp-brake-invadvertent disabling of brake shift interlock. *mj02176 · Technical service bulletin · Exterior Lighting · issued Sep 2, 2002
- 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. *tt02142 · Technical service bulletin · Engine and Engine Cooling · issued Jul 22, 2002
- 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 inc…15887 · Technical service bulletin · Power Train · issued May 1, 2002
- 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…0282 · Technical service bulletin · Power Train · issued Apr 29, 2002
- Engine oil system priming procedures, service tips for reports of premature engine failure. *tt01246 · Technical service bulletin · Engine and Engine Cooling · issued Dec 10, 2001
- Some vehicles equipped with the 4.0l ohv engine may exhibit an engine noise which may be perceived by the customer as a piston / onnecting rod bearing knock. *tt01197 · Technical service bulletin · Engine and Engine Cooling · issued Oct 1, 2001
- Brake shift interlock.*jb01181 · Technical service bulletin · Power Train · issued Sep 17, 2001
- Information regarding transmission fluid usage charts. *slc01157 · Technical service bulletin · Unknown OR Other · issued Aug 6, 2001
- Some vehicles may exhibit heater core leaks. *slc01156 · Technical service bulletin · Visibility · issued Aug 6, 2001
- 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. *tt01124 · Technical service bulletin · Engine and Engine Cooling · issued Jun 25, 2001
- Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt002310 · Technical service bulletin · Power Train · issued Nov 13, 2000
- Information regarding pump alignment tools. **mr8164 · Technical service bulletin · Unknown OR Other · issued Apr 1, 2000
- Information regarding the new transmission cooler flusher- service tip. *mjs0015 · Technical service bulletin · Power Train · issued Jan 10, 2000
- Information on replacing and / or repairing malfunctioning (door, ignition and decklid) locks. *tt99242 · Technical service bulletin · Structure · issued Nov 15, 1999
- During extreme cold ambient temperatures and under certain driving conditions, moisture in the crankcase may enter the pcv system, freeze and cause presure in the engine crankcase.…99235 · Technical service bulletin · Vehicle Speed Control · issued Nov 15, 1999
- Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt99222 · Technical service bulletin · Electrical System · issued Oct 18, 1999
- Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt99196 · Technical service bulletin · Equipment · issued Sep 20, 1999
- Information for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement. *tt99194 · Technical service bulletin · Service Brakes, Hydraulic · issued Sep 20, 1999
- Service tip information on revised oil pan gasket replacement procedure. *tt99183 · Technical service bulletin · Engine and Engine Cooling · issued Sep 6, 1999
- Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs13180 · Technical service bulletin · Engine and Engine Cooling · issued Sep 1, 1999
- Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt6997 · Technical service bulletin · Engine and Engine Cooling · issued Sep 1, 1999
- Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt13118 · Technical service bulletin · Engine and Engine Cooling · issued Aug 1, 1999
- Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt6896 · Technical service bulletin · Engine and Engine Cooling · issued Aug 1, 1999
- Information on the new flush and fill tool available through rotunda. *tt99152 · Technical service bulletin · Power Train · issued Jul 26, 1999
- Conditions with the brake lamps inadvertently disabling the brake shift interlock. *tt99139 · Technical service bulletin · Exterior Lighting · issued Jun 28, 1999
- Ford motor company has released a private labeled material to be used for iron particle / acid rain service repairs. *tt991210 · Technical service bulletin · Unknown OR Other · issued Jun 14, 1999
- 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. *tt99129 · Technical service bulletin · Equipment · issued Jun 14, 1999
- Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt99816 · Technical service bulletin · Engine and Engine Cooling · issued May 3, 1999
- Subject regarding door trim panel replacement - service tip. *tt99-8-15 · Technical service bulletin · Structure · issued May 3, 1999
- Information regarding reprogramming powertrain control modules (pcms). *tt9943 · Technical service bulletin · Power Train · issued Mar 8, 1999
- Information on servicing oil pan gasket leaks. *tt5518 · Technical service bulletin · Engine and Engine Cooling · issued Mar 1, 1999
- Ford motor company has released a new electrical grease ( f8az - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals. *yc98246 · Technical service bulletin · Electrical System · issued Dec 7, 1998
- Information regarding replacement and / or repairs on any lock component. *yc982323 · Technical service bulletin · Structure · issued Nov 23, 1998
- Mass air flow (maf)- sensor contamination- service tip. *ak982310 · Technical service bulletin · Engine and Engine Cooling · issued Nov 23, 1998
- Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles. *yc98233 · Technical service bulletin · Power Train · issued Nov 23, 1998
- Experiencing a " buzzing " or " rattling " noise from the exhaust system. *yc982010 · Technical service bulletin · Engine and Engine Cooling · issued Oct 12, 1998
- LOCKS FAILED. YD98163 · Technical service bulletin · Structure · issued Aug 17, 1998
- Information on a new transmission fluid usage chart. *yc9888 · Technical service bulletin · Power Train · issued Apr 27, 1998
- Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio. *tt9873 · Technical service bulletin · Equipment · issued Apr 13, 1998
- Information on tire company telephone numbers for customer assistance. *yc9852 · Technical service bulletin · Tires · issued Apr 13, 1998
- Information on a buzzing or rattle noise from the exhaust system. *tt9864 · Technical service bulletin · Engine and Engine Cooling · issued Mar 30, 1998
- This bulletin contains service tips when servicing any brake related roughness / pull concerns. *tt985A52 · Technical service bulletin · Service Brakes, Hydraulic · issued Mar 18, 1998
- The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc985A13 · Technical service bulletin · Service Brakes, Hydraulic · issued Mar 18, 1998
- Recommended guidelines for towing behind recreational vehicles. *tt985A12 · Technical service bulletin · Equipment · issued Mar 18, 1998
- Service tip information regarding elimination of sanding rotors and drums. *yc985A11 · Technical service bulletin · Service Brakes, Hydraulic · issued Mar 18, 1998
- Hub-mount brake rotor machining equipment from rotunda is now approved for warranty and service use. *yc985A5 · Technical service bulletin · Service Brakes, Hydraulic · issued Mar 18, 1998
- Availability of hub-mount brake rotor machining equipment. *yc9845 · Technical service bulletin · Service Brakes, Air · issued Mar 2, 1998
- Information regarding transfer case rear housing and driveshaft replacement. *tt983080 · Technical service bulletin · Power Train · issued Feb 26, 1998
- Front and rear bumpers made of xenoy plastic have had the conductive primer removed from service parts. *yc9832 · Technical service bulletin · Structure · issued Feb 16, 1998
- Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt98112 · Technical service bulletin · Power Train · issued Jan 19, 1998
- Subject regarding the availability of hub-mount brake rotor machining equipment. *tt9814 · Technical service bulletin · Service Brakes, Hydraulic · issued Jan 19, 1998
- Vehicles exhibiting a "squeaking" or "chirping" from the blower motor at low blower motor speeds. *yc97111097234 · Technical service bulletin · Electrical System · issued Nov 10, 1997
- Experiencing a "thumping" noise or tempeature gauge fluctation with some vehicles. *yc97090297189 · Technical service bulletin · Engine and Engine Cooling · issued Sep 2, 1997
- 3.0l vehicles setting misfire codes p0300-p0306 should be serviced using normal diagnostics. *twBC2436970501 · Technical service bulletin · Unknown OR Other · issued May 1, 1997
- Aerostar e4wd models may experience front axle lubricant leakage from the vent tube under some driving conditions. *twBC2431970501 · Technical service bulletin · Power Train · issued May 1, 1997
- The air operated cooling fan mayu run continuously if the engine ecm fan control parameters are set incorrectly. *twBC2394970501 · Technical service bulletin · Visibility · issued May 1, 1997
- Fuel injection pump- bosch- service information for fd1060/1460 diesel engines. *jd97716 · Technical service bulletin · Engine and Engine Cooling · issued Mar 31, 1997
- Blower motor- "chirping" or "squeaking" from blower motor at low speeds. *jd97610 · Technical service bulletin · Engine and Engine Cooling · issued Mar 17, 1997
- Fuel economy- customer expectations versus vehicle usage. *jd9768 · Technical service bulletin · Unknown OR Other · issued Mar 17, 1997
- Fluid- transmission fluid usage charts. *jd97511 · Technical service bulletin · Power Train · issued Mar 3, 1997
- Frame- rivet replacement with bolts- service tips. *jd9747 · Technical service bulletin · Structure · issued Feb 17, 1997
- WINDSHIELD CRACKS. *TWBC3234970211 · Technical service bulletin · Visibility · issued Feb 11, 1997
- Fd 1460 engines - non-functioning air intake heaters - ensure that the diagnostic switch is in off position. *twBC3244970210 · Technical service bulletin · Engine and Engine Cooling · issued Feb 10, 1997
- Air conditioning- r-134a tracer dye installed in a/c system and three o-ring spring lock couplers- service tip. *jd9735 · Technical service bulletin · Equipment · issued Feb 3, 1997
- MISFIRE CODES P0300-P0306. *TWBC031A597020 · Technical service bulletin · Electrical System · issued Feb 1, 1997
- Recall 96e58 - low volume recall - 229 vehicles involved - reissue of recall documentation to dealers. *tw96E58 · Technical service bulletin · Unknown OR Other · issued Feb 1, 1997
- 4.0l equipped vehicles may experience temperature gauge fluctuation that may be accompnied with a thumping noise or feel in the coolant hoses with the engine at normal operating te…BC1019997230 · Technical service bulletin · Engine and Engine Cooling · issued Jan 23, 1997
- 4.0l equipped vehicles may experience temperature gauge fluctuation that may be accompanied with a thumping noise or feel in the coolant hose with the engine at normal operating te…BC3485972301 · Technical service bulletin · Engine and Engine Cooling · issued Jan 23, 1997
- Interior trim panels are occasionally being reported with issues of damage/delamination/holes. *jdBC0344972301 · Technical service bulletin · Seats · issued Jan 23, 1997
- Misfire codes p0300-p0306- reprogramming procedures do not apply to aerostar3.0l calibrations. *jdBC0315972301 · Technical service bulletin · Electrical System · issued Jan 23, 1997
- Cold engine knock/tick noise. *jdBC0324970201 · Technical service bulletin · Engine and Engine Cooling · issued Jan 2, 1997
- Vehicle electrical system, several megafuses are used. Now has a new plastic cover. *jdBC0191970201 · Technical service bulletin · Electrical System · issued Jan 2, 1997
- Engine - 4.0l - torque-to-yield (tty) crankshaft damper bolt. *tw962619 · Technical service bulletin · Engine and Engine Cooling · issued Dec 16, 1996
- Brakes - brake service - service tips. *tw962617 · Technical service bulletin · Service Brakes, Hydraulic · issued Dec 16, 1996
- Sliding door - damaged or misadjusted latch mechanism. *tw962616 · Technical service bulletin · Latches/locks/linkages · issued Dec 16, 1996
- Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw962612 · Technical service bulletin · Power Train · issued Dec 16, 1996
- Engine - 4.0l - new torque-to-yield connecting rod fasteners. *tw962524 · Technical service bulletin · Engine and Engine Cooling · issued Dec 2, 1996
- Powertrain control module -reprogram powertrain control module (pcm) - service procedures - service tip. *tw962511 · Technical service bulletin · Electrical System · issued Dec 2, 1996
- 1996-1997 aerostar interior trim panels are occasionally being reported with issues of damage/delamination/holes. *twBC0344961127 · Technical service bulletin · Structure · issued Nov 27, 1996
- Torque converter - leak test procedure - service tip. *tw96249 · Technical service bulletin · Power Train · issued Nov 18, 1996
- Wiring - electrical diode identification and service replacements. *tw96246 · Technical service bulletin · Electrical System · issued Nov 18, 1996
- Instructions for replacing diagnosed failed parts. *twBC0407961115 · Technical service bulletin · Engine and Engine Cooling · issued Nov 15, 1996
- Instructions for replacing diagnosed failed component. *twBC0490961112 · Technical service bulletin · Engine and Engine Cooling · issued Nov 12, 1996
- Diagnostic instructions for servicing evaporative emission purge flow system. *twBC9714961101 · Technical service bulletin · Engine and Engine Cooling · issued Nov 1, 1996
- Cold engine knock/tick noise. *twBC0324961101 · Technical service bulletin · Engine and Engine Cooling · issued Nov 1, 1996
- Check engine light, code p030x, with no driveability complaint. *twBC0313961101 · Technical service bulletin · Electrical System · issued Nov 1, 1996
- Air conditioning - compressor failure - insufficient amount of refrigerant oil. *tw96226 · Technical service bulletin · Equipment · issued Oct 21, 1996
- Mass air flow sensor - replacement as an assembly - service tip. *tw96225 · Technical service bulletin · Fuel System, Gasoline · issued Oct 21, 1996
- Long crank - sticking idle air control (iac) valve - vehicles built from 11/1/94 through 3/30/96 -stall - after starting when engine allowed to soak from 1-4 hours - sticking idle …96223 · Technical service bulletin · Vehicle Speed Control · issued Oct 21, 1996
- Brakes - elimination of sanding rotors and drums - service tip. *tw96222 · Technical service bulletin · Service Brakes, Hydraulic · issued Oct 21, 1996
- Windshield and interior glass - fog/film. *tw96221 · Technical service bulletin · Visibility · issued Oct 21, 1996
- Concerns of a/c going to defrost mode when climbing grades or accelerating are likely caused by vacuum leaks. *ttBC0766961016 · Technical service bulletin · Equipment · issued Oct 16, 1996
- Lack of cooling due to complete loss of charge. May have a machining defect in the high pressure relief valve. *ttBC0880961004 · Technical service bulletin · Engine and Engine Cooling · issued Oct 4, 1996
- Information for when diagnosing concerns w/ factory installed cellular phones. *ttBC9688961001 · Technical service bulletin · Equipment · issued Oct 1, 1996
- 2.5l duratec engine exchanges no longer include front end accessory drive component, oil level indicator, water pump belt/tensioner, egr tube, linkshaft bracket or exhaust manifold…BC9666961001 · Technical service bulletin · Engine and Engine Cooling · issued Oct 1, 1996
- For concerns of stalling, reflash pcm w/ 1996 calibration (r11 level). *ttBC5191961001 · Technical service bulletin · Power Train · issued Oct 1, 1996
- 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. Failure to change over or conv…96726 · Technical service bulletin · Power Train · issued Mar 25, 1996
- Experiencing a rapping or clanging noise when the steering wheel is turned rapidly or when turning on a bumpy road surface. *tt96719 · Technical service bulletin · Steering · issued Mar 25, 1996
- The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake sys…95212 · Technical service bulletin · Service Brakes, Hydraulic · issued Oct 1, 1995
- On transmissions built before 6/20/95 (fig 1) an extended shift and a higher engine rpm than expected and/or no shift condition, possibly along with a flashing 'o/d off' lamp and/o…951912 · Technical service bulletin · Power Train · issued Sep 1, 1995