1996 Ford Aerostar
1996 Ford Aerostar TSBs (Technical Service Bulletins)
There are also 6 Ford recalls » 2 defect investigations » 104 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 title & date, & either contact your local dealer or click on the links below.
ALSO: The TSB numbers are the NHTSA numbers, which are different from the TSB numbers the manufacturers use to track each bulletin -- yes, it's a very screwed up situation that's almost completely unhelpful to you as the consumer. 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
SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE LIGHT
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
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
SERVICE BRAKES, AIR:DISC:ROTOR
ENGINE AND ENGINE COOLING:ENGINE
- TSB #02221 -- ENGINE-GEAR DRIVEN SYNCHRONIZERS-INCORRECT INSTALLATION-CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION. *MJ (NHTSA ID #10008304, NOVEMBER 11 2002)
- TSB #870197 -- 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 (NHTSA ID #10000592, OCTOBER 22 2002)
- 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 #13180 -- INFORMATION REGARDING CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART. *MJS (NHTSA ID #6090538, SEPTEMBER 01 1999)
- TSB #6997 -- SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR ALIGNMENT TOOL FOR VEHICLES WITH VARIOUS ENGINE SIZES. *TT (NHTSA ID #6090310, SEPTEMBER 01 1999)
- TSB #5518 -- INFORMATION ON SERVICING OIL PAN GASKET LEAKS. *TT (NHTSA ID #605190, MARCH 01 1999)
- TSB #97610 -- BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS. *JD (NHTSA ID #51990, MARCH 17 1997)
- TSB #BC3244970210 -- FD 1460 ENGINES - NON-FUNCTIONING AIR INTAKE HEATERS - ENSURE THAT THE DIAGNOSTIC SWITCH IS IN OFF POSITION. *TW (NHTSA ID #51866, FEBRUARY 10 1997)
- TSB #BC0324970201 -- COLD ENGINE KNOCK/TICK NOISE. *JD (NHTSA ID #51128, JANUARY 02 1997)
- TSB #962619 -- ENGINE - 4.0L - TORQUE-TO-YIELD (TTY) CRANKSHAFT DAMPER BOLT. *TW (NHTSA ID #51003, DECEMBER 16 1996)
- TSB #962524 -- ENGINE - 4.0L - NEW TORQUE-TO-YIELD CONNECTING ROD FASTENERS. *TW (NHTSA ID #50980, DECEMBER 02 1996)
- TSB #BC9666961001 -- 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 MANIFOLDS. *TT (NHTSA ID #50527, OCTOBER 01 1996)
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 #01246 -- ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT (NHTSA ID #630515, DECEMBER 10 2001)
- 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 #BC0324961101 -- COLD ENGINE KNOCK/TICK NOISE. *TW (NHTSA ID #50732, NOVEMBER 01 1996)
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
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)
- TSB #BC0880961004 -- LACK OF COOLING DUE TO COMPLETE LOSS OF CHARGE. MAY HAVE A MACHINING DEFECT IN THE HIGH PRESSURE RELIEF VALVE. *TT (NHTSA ID #50437, OCTOBER 04 1996)
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE
- 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)
- 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)
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)
- TSB #9864 -- INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT (NHTSA ID #601312, MARCH 30 1998)
- TSB #BC0407961115 -- INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED PARTS. *TW (NHTSA ID #50753, NOVEMBER 15 1996)
- TSB #BC0490961112 -- INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED COMPONENT. *TW (NHTSA ID #50763, NOVEMBER 12 1996)
- TSB #BC9714961101 -- DIAGNOSTIC INSTRUCTIONS FOR SERVICING EVAPORATIVE EMISSION PURGE FLOW SYSTEM. *TW (NHTSA ID #50860, NOVEMBER 01 1996)
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
POWER TRAIN
- TSB #15887 -- 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 (NHTSA ID #637755, MAY 01 2002)
- TSB #0282 -- 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 (NHTSA ID #637922, APRIL 29 2002)
- TSB #9943 -- INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT (NHTSA ID #604751, MARCH 08 1999)
POWER TRAIN:MANUAL TRANSMISSION
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 #BC5191961001 -- FOR CONCERNS OF STALLING, REFLASH PCM W/ 1996 CALIBRATION (R11 LEVEL). *TT (NHTSA ID #50469, OCTOBER 01 1996)
- TSB #96726 -- 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 CONVERT THE FLUID PAN MAY RESULT IN A TRANSMISSION FLUID LEAK (NHTSA ID #613348, MARCH 25 1996)
- TSB #951912 -- 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/OR THE DIAGNOSTIC TROUBLE CODES (DTCS) LISTED ABOVE, MAY OCC (NHTSA ID #46468, SEPTEMBER 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
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
ELECTRICAL SYSTEM:STARTER ASSEMBLY
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:FUSES AND CIRCUIT BREAKERS
ELECTRICAL SYSTEM:IGNITION
- TSB #BC031A597020 -- MISFIRE CODES P0300-P0306. *TW (NHTSA ID #51653, FEBRUARY 01 1997)
- TSB #BC0315972301 -- MISFIRE CODES P0300-P0306- REPROGRAMMING PROCEDURES DO NOT APPLY TO AEROSTAR3.0L CALIBRATIONS. *JD (NHTSA ID #51424, JANUARY 23 1997)
ELECTRICAL SYSTEM:IGNITION:MODULE
- TSB #962511 -- POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP. *TW (NHTSA ID #50968, DECEMBER 02 1996)
- TSB #BC0313961101 -- CHECK ENGINE LIGHT, CODE P030X, WITH NO DRIVEABILITY COMPLAINT. *TW (NHTSA ID #50721, NOVEMBER 01 1996)
EXTERIOR LIGHTING:BRAKE LIGHTS
VISIBILITY:WINDSHIELD
- TSB #BC3234970211 -- WINDSHIELD CRACKS. *TW (NHTSA ID #51859, FEBRUARY 11 1997)
- TSB #96221 -- WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW (NHTSA ID #50940, OCTOBER 21 1996)
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:HEATER CORE
STRUCTURE
STRUCTURE:BODY
- TSB #982323 -- INFORMATION REGARDING REPLACEMENT AND / OR REPAIRS ON ANY LOCK COMPONENT. *YC (NHTSA ID #603930, NOVEMBER 23 1998)
- TSB #BC0344961127 -- 1996-1997 AEROSTAR INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES. *TW (NHTSA ID #50741, NOVEMBER 27 1996)
STRUCTURE:BODY:BUMPERS
STRUCTURE:BODY:DOOR
- TSB #99242 -- INFORMATION ON REPLACING AND / OR REPAIRING MALFUNCTIONING (DOOR, IGNITION AND DECKLID) LOCKS. *TT (NHTSA ID #6090184, NOVEMBER 15 1999)
- TSB #99-8-15 -- SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP. *TT (NHTSA ID #606419, MAY 03 1999)
- TSB #98163 -- LOCKS FAILED. YD (NHTSA ID #6090873, AUGUST 17 1998)
LATCHES/LOCKS/LINKAGES:DOORS:LATCH
VEHICLE SPEED CONTROL:LINKAGES
VEHICLE SPEED CONTROL:CRUISE CONTROL
TIRES
SEATS
EQUIPMENT:ELECTRICAL
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 #9735 -- AIR CONDITIONING- R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE O-RING SPRING LOCK COUPLERS- SERVICE TIP. *JD (NHTSA ID #51662, FEBRUARY 03 1997)
- TSB #96226 -- AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL. *TW (NHTSA ID #50945, OCTOBER 21 1996)
- TSB #BC0766961016 -- CONCERNS OF A/C GOING TO DEFROST MODE WHEN CLIMBING GRADES OR ACCELERATING ARE LIKELY CAUSED BY VACUUM LEAKS. *TT (NHTSA ID #50402, OCTOBER 16 1996)
EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES
UNKNOWN OR OTHER
- TSB #01157 -- INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC (NHTSA ID #623988, AUGUST 06 2001)
- TSB #8164 -- INFORMATION REGARDING PUMP ALIGNMENT TOOLS. **MR (NHTSA ID #613621, APRIL 01 2000)
- TSB #991210 -- FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS. *TT (NHTSA ID #606461, JUNE 14 1999)
- TSB #BC2436970501 -- 3.0L VEHICLES SETTING MISFIRE CODES P0300-P0306 SHOULD BE SERVICED USING NORMAL DIAGNOSTICS. *TW (NHTSA ID #52837, MAY 01 1997)
- TSB #9768 -- FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD (NHTSA ID #51987, MARCH 17 1997)
- TSB #96E58 -- RECALL 96E58 - LOW VOLUME RECALL - 229 VEHICLES INVOLVED - REISSUE OF RECALL DOCUMENTATION TO DEALERS. *TW (NHTSA ID #51585, FEBRUARY 01 1997)