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1994 Ford Aerostar

Technical Service Bulletins

There are also 6 Ford recalls » 6 defect investigations » 75 TSBs » for the Ford Aerostar.

Please note: The TSB information displayed below are summaries. Unfortunately we do not have access to the full versions. To get full information about a particular TSB, write down the TSB number & contact your local dealer.

ALSO: The TSB numbers are the NHTSA numbers, which are different from the TSB numbers the manufacturers use. The manufacturers don't give out their TSB numbers to us, so if you ask your dealer for more information about a TSB, have them look it up by the issue date or the TSB title.

STEERING

• TSB #96719 -- EXPERIENCING A RAPPING OR CLANGING NOISE WHEN THE STEERING WHEEL IS TURNED RAPIDLY OR WHEN TURNING ON A BUMPY ROAD SURFACE. *TT (NHTSA ID #613340, MARCH 25 1996)

STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

• TSB #BC1383950906 -- VEHICLE MAY EXHIBIT A MOAN WHEN TURNING - TO CORRECT THIS CONDITION, REPLACE THE HIGH PRESSURE HOSE WITH A TUNED HOSE. *TW (NHTSA ID #45748, SEPTEMBER 01 1995)

SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE LIGHT

• TSB #02176 -- LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ (NHTSA ID #10008580, SEPTEMBER 02 2002)

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

• TSB #99194 -- INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT. *TT (NHTSA ID #6090082, SEPTEMBER 20 1999)
• TSB #985A11 -- SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS. *YC (NHTSA ID #601009, MARCH 18 1998)
• TSB #985A52 -- THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS. *TT (NHTSA ID #613023, MARCH 18 1998)
• TSB #962617 -- BRAKES - BRAKE SERVICE - SERVICE TIPS. *TW (NHTSA ID #51002, DECEMBER 16 1996)
• TSB #96222 -- BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP. *TW (NHTSA ID #50941, OCTOBER 21 1996)

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC

• TSB #985A13 -- THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC (NHTSA ID #601012, MARCH 18 1998)

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

• TSB #985A5 -- HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE. *YC (NHTSA ID #601003, MARCH 18 1998)
• TSB #9814 -- SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *TT (NHTSA ID #605562, JANUARY 19 1998)

SERVICE BRAKES, HYDRAULIC:ANTILOCK

• TSB #95212 -- 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 SYSTEM. IF PETROLEUM-BASED GREASE IS USED TO LUBRICATE ANY PAR (NHTSA ID #46478, OCTOBER 01 1995)

ENGINE AND ENGINE COOLING:ENGINE

• TSB #01124 -- 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. *TT (NHTSA ID #622665, JUNE 25 2001)
• TSB #97610 -- BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS. *JD (NHTSA ID #51990, MARCH 17 1997)
• TSB #9743 -- BLOWER MOTOR- "CHIRP" OR "SQUEAK" FROM BLOWER MOTOR AT LOW SPEEDS. *JD (NHTSA ID #51682, FEBRUARY 17 1997)
• TSB #95910 -- UNKNOWN (NHTSA ID #42083, MAY 01 1995)

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

• TSB #02142 -- 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. *TT (NHTSA ID #635982, JULY 22 2002)
• TSB #01197 -- 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. *TT (NHTSA ID #627752, OCTOBER 01 2001)
• TSB #99183 -- SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT (NHTSA ID #6090051, SEPTEMBER 06 1999)
• TSB #13118 -- SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT (NHTSA ID #6091931, AUGUST 01 1999)
• TSB #6896 -- SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT (NHTSA ID #608921, AUGUST 01 1999)
• TSB #99816 -- FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT (NHTSA ID #606420, MAY 03 1999)
• TSB #95320 -- KNOCKING NOISE FROM LOWER FRONT OF ENGINE COMPARTMENT. *TW (NHTSA ID #39229, FEBRUARY 01 1995)
• TSB #94256 -- KNOCKING NOISE FROM LOWER END #1 MAIN BEARING DURING ACCELERATION. *TW (NHTSA ID #38057, DECEMBER 01 1994)

ENGINE AND ENGINE COOLING:COOLING SYSTEM

• TSB #97090297189 -- EXPERIENCING A "THUMPING" NOISE OR TEMPEATURE GAUGE FLUCTATION WITH SOME VEHICLES. *YC (NHTSA ID #54075, SEPTEMBER 02 1997)

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

• TSB #9524 -- NEW RADIATOR MANUFACTURING PROCESS/MODIFICATION. *TW (NHTSA ID #39120, JANUARY 01 1995)

ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE

• TSB #BC3485972301 -- 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 TEMPERATURE. *JD (NHTSA ID #51482, JANUARY 23 1997)
• TSB #BC1019997230 -- 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 TEMPERATURE. *JD (NHTSA ID #51559, JANUARY 23 1997)

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

• TSB #982010 -- EXPERIENCING A " BUZZING " OR " RATTLING " NOISE FROM THE EXHAUST SYSTEM. *YC (NHTSA ID #603695, OCTOBER 12 1998)

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

• TSB #982310 -- MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK (NHTSA ID #603724, NOVEMBER 23 1998)

FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM

• TSB #96225 -- MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP. *TW (NHTSA ID #50944, OCTOBER 21 1996)

POWER TRAIN:MANUAL TRANSMISSION

• TSB #BC0678961025 -- INFORMATION ON AODE/4R7W TRANSMISSION MAIN CONTROL & CASE REPLACEMENT. *TT (NHTSA ID #50356, OCTOBER 25 1996)

POWER TRAIN:AUTOMATIC TRANSMISSION

• TSB #0015 -- INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS (NHTSA ID #612203, JANUARY 10 2000)
• TSB #99152 -- INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT (NHTSA ID #608431, JULY 26 1999)
• TSB #9888 -- INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC (NHTSA ID #601238, APRIL 27 1998)
• TSB #983080 -- INFORMATION REGARDING TRANSFER CASE REAR HOUSING AND DRIVESHAFT REPLACEMENT. *TT (NHTSA ID #607372, FEBRUARY 26 1998)
• TSB #98112 -- SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED. *TT (NHTSA ID #605573, JANUARY 19 1998)
• TSB #97511 -- FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD (NHTSA ID #51945, MARCH 03 1997)
• TSB #BC1350950906 -- HIGH ALTITUDE TRANSMISSION AVAILABLE. *TW (NHTSA ID #45756, SEPTEMBER 01 1995)
• TSB #951012 -- TRANSFER CASE MAY LEAK FLUID FROM THE CASE VENT TUBE. *TW (NHTSA ID #42097, MAY 01 1995)

POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

• TSB #03148 -- NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT (NHTSA ID #10003748, JULY 21 2003)
• TSB #002310 -- SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT (NHTSA ID #616522, NOVEMBER 13 2000)

POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

• TSB #962612 -- TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW (NHTSA ID #50997, DECEMBER 16 1996)
• TSB #96249 -- TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW (NHTSA ID #50908, NOVEMBER 18 1996)

POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START SWITCH

• TSB #01181 -- BRAKE SHIFT INTERLOCK.*JB (NHTSA ID #625715, SEPTEMBER 17 2001)

POWER TRAIN:AXLE ASSEMBLY

• TSB #98233 -- CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES. *YC (NHTSA ID #603717, NOVEMBER 23 1998)
• TSB #BC2431970501 -- AEROSTAR E4WD MODELS MAY EXPERIENCE FRONT AXLE LUBRICANT LEAKAGE FROM THE VENT TUBE UNDER SOME DRIVING CONDITIONS. *TW (NHTSA ID #52834, MAY 01 1997)

ELECTRICAL SYSTEM

• TSB #98246 -- FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC (NHTSA ID #604059, DECEMBER 07 1998)

ELECTRICAL SYSTEM:STARTER ASSEMBLY

• TSB #97111097234 -- VEHICLES EXHIBITING A "SQUEAKING" OR "CHIRPING" FROM THE BLOWER MOTOR AT LOW BLOWER MOTOR SPEEDS. *YC (NHTSA ID #53660, NOVEMBER 10 1997)

ELECTRICAL SYSTEM:WIRING

• TSB #99222 -- SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT (NHTSA ID #6089681, OCTOBER 18 1999)
• TSB #96246 -- WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW (NHTSA ID #50905, NOVEMBER 18 1996)

ELECTRICAL SYSTEM:IGNITION

• TSB #95102 -- VEHICLES MAY HAVE A DISCONNECT OF THE IGNITION CONTROL MODULE (ICM) CONNECTOR OR MOISTURE BUILDUP WITHIN THE CONNECTOR. *TW (NHTSA ID #42087, MAY 01 1995)

ELECTRICAL SYSTEM:IGNITION:MODULE

• TSB #95715 -- MIL LAMP MAY TURN ON OR FLASH INTERMITTENTLY MAY BE DUE TO THE POWERTRAIN CONTROL MODULE (PCM) INCORRECTLY CALCULATING THE VEHICLE ENGINE LOAD DURING LIGHT THROTTLE. *TW (NHTSA ID #41015, APRIL 01 1995)

EXTERIOR LIGHTING:BRAKE LIGHTS

• TSB #99139 -- CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK. *TT (NHTSA ID #606508, JUNE 28 1999)

VISIBILITY:WINDSHIELD

• TSB #96221 -- WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW (NHTSA ID #50940, OCTOBER 21 1996)

VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

• TSB #94249 -- FRONT DOOR GLASS TIPPING AND BINDING DURING DOWNWARD TRAVEL. *TW (NHTSA ID #37761, NOVEMBER 01 1994)

VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:BLOWER

• TSB #9592 -- UNKNOWN (NHTSA ID #42077, MAY 01 1995)
• TSB #95511 -- CHIRP OR SQUEAK FROM BLOWER MOTOR. *TW (NHTSA ID #39884, MARCH 01 1995)
• TSB #9566 -- CHIRP OR SQUEAK NOISE FROM BLOWER MOTOR AT LOW SPEEDS. *TW (NHTSA ID #39903, MARCH 01 1995)
• TSB #9566 -- UNKNOWN (NHTSA ID #3057200, MARCH 01 1995)

VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:HEATER CORE

• TSB #01156 -- SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC (NHTSA ID #623944, AUGUST 06 2001)

STRUCTURE

• TSB #9747 -- FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD (NHTSA ID #51689, FEBRUARY 17 1997)

STRUCTURE:BODY

• TSB #95217 -- A WINDNOISE MAY BE HEARD AT THE A-PILLAR IN SOME VEHICLES. THIS MAY BE CAUSED BY INCOMPLETE SEALING AT THE A-PILLAR. INSTALL A FOAM SEALANT INTO THE LOWER SECTION OF THE A-PILLAR TO SEAL AN AIR LEAK IN THE A-PILLAR. (NHTSA ID #46480, OCTOBER 01 1995)

STRUCTURE:BODY:BUMPERS

• TSB #9832 -- FRONT AND REAR BUMPERS MADE OF XENOY PLASTIC HAVE HAD THE CONDUCTIVE PRIMER REMOVED FROM SERVICE PARTS. *YC (NHTSA ID #600586, FEBRUARY 16 1998)

STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE

• TSB #BC0822961010 -- CONCERNS W/ LIFTGATE OPENING EFFORTS &/OR THE LIFTGATE NOT STAYING OPEN, ESPECIALLY IN COLD AMBIENT TEMPS. *TT (NHTSA ID #50417, OCTOBER 10 1996)

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

• TSB #962616 -- SLIDING DOOR - DAMAGED OR MISADJUSTED LATCH MECHANISM. *TW (NHTSA ID #51001, DECEMBER 16 1996)

TIRES

• TSB #9852 -- INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC (NHTSA ID #601290, APRIL 13 1998)

EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

• TSB #99129 -- 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. *TT (NHTSA ID #606460, JUNE 14 1999)
• TSB #9873 -- EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT (NHTSA ID #601341, APRIL 13 1998)

EQUIPMENT:ELECTRICAL:AIR CONDITIONER

• TSB #99196 -- INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT (NHTSA ID #6090087, SEPTEMBER 20 1999)
• TSB #96226 -- AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL. *TW (NHTSA ID #50945, OCTOBER 21 1996)

EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES

• TSB #985A12 -- RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT (NHTSA ID #601010, MARCH 18 1998)

UNKNOWN OR OTHER

• TSB #01157 -- INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC (NHTSA ID #623988, AUGUST 06 2001)
• TSB #98L20 -- SPECIAL FIELD ACTION REGARDING REVISED WARANTY INFORMATION. *TT (NHTSA ID #616508, DECEMBER 01 1998)
• TSB #9768 -- FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD (NHTSA ID #51987, MARCH 17 1997)