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1996 Ford Aerostar
105 Technical Service Bulletins (TSBs)
TSB List for the 1996 Ford Aerostar
Technical Service Bulletins (TSBs) for the 1996 Aerostar are official communications between Ford & their dealerships that describe processes for troubleshooting or fixing certain common problems. All vehicle manufacturers are required by U.S. law to make their TSBs available to the public.
STEERING
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TSB #96719
EXPERIENCING A RAPPING OR CLANGING NOISE WHEN THE STEERING WHEEL IS TURNED RAPIDLY OR WHEN TURNING ON A BUMPY ROAD SURFACE. *TT Read More »
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
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TSB #99194
INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT. *TT Read More »
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TSB #985A11
SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS. *YC Read More »
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TSB #985A52
THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS. *TT Read More »
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TSB #962617
BRAKES - BRAKE SERVICE - SERVICE TIPS. *TW Read More »
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TSB #96222
BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP. *TW Read More »
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC
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TSB #985A13
THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC Read More »
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
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TSB #985A5
HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE. *YC Read More »
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TSB #9814
SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *TT Read More »
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
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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. Read More »
SERVICE BRAKES, AIR:DISC:ROTOR
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TSB #9845
AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *YC Read More »
ENGINE AND ENGINE COOLING:ENGINE
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TSB #02221
ENGINE-GEAR DRIVEN SYNCHRONIZERS-INCORRECT INSTALLATION-CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION. *MJ Read More »
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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. Read More »
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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 Read More »
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TSB #6997
SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR ALIGNMENT TOOL FOR VEHICLES WITH VARIOUS ENGINE SIZES. *TT Read More »
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TSB #13180
INFORMATION REGARDING CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART. *MJS Read More »
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TSB #5518
INFORMATION ON SERVICING OIL PAN GASKET LEAKS. *TT Read More »
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TSB #97610
BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS. *JD Read More »
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TSB #BC3244970210
FD 1460 ENGINES - NON-FUNCTIONING AIR INTAKE HEATERS - ENSURE THAT THE DIAGNOSTIC SWITCH IS IN OFF POSITION. *TW Read More »
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TSB #BC0324970201
COLD ENGINE KNOCK/TICK NOISE. *JD Read More »
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TSB #962619
ENGINE - 4.0L - TORQUE-TO-YIELD (TTY) CRANKSHAFT DAMPER BOLT. *TW Read More »
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TSB #962524
ENGINE - 4.0L - NEW TORQUE-TO-YIELD CONNECTING ROD FASTENERS. *TW Read More »
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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 Read More »
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
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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 Read More »
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TSB #01246
ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT Read More »
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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 Read More »
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TSB #99183
SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT Read More »
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TSB #6896
SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT Read More »
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TSB #13118
SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT Read More »
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TSB #99816
FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT Read More »
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TSB #BC0324961101
COLD ENGINE KNOCK/TICK NOISE. *TW Read More »
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
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TSB #97716
FUEL INJECTION PUMP- BOSCH- SERVICE INFORMATION FOR FD1060/1460 DIESEL ENGINES. *JD Read More »
ENGINE AND ENGINE COOLING:COOLING SYSTEM
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TSB #97090297189
EXPERIENCING A "THUMPING" NOISE OR TEMPEATURE GAUGE FLUCTATION WITH SOME VEHICLES. *YC Read More »
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TSB #BC0880961004
LACK OF COOLING DUE TO COMPLETE LOSS OF CHARGE. MAY HAVE A MACHINING DEFECT IN THE HIGH PRESSURE RELIEF VALVE. *TT Read More »
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS
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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 Read More »
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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 Read More »
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
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TSB #982010
EXPERIENCING A " BUZZING " OR " RATTLING " NOISE FROM THE EXHAUST SYSTEM. *YC Read More »
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TSB #9864
INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT Read More »
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TSB #BC0407961115
INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED PARTS. *TW Read More »
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TSB #BC0490961112
INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED COMPONENT. *TW Read More »
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TSB #BC9714961101
DIAGNOSTIC INSTRUCTIONS FOR SERVICING EVAPORATIVE EMISSION PURGE FLOW SYSTEM. *TW Read More »
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
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TSB #982310
MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK Read More »
FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
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TSB #96225
MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP. *TW Read More »
POWER TRAIN
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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). Read More »
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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. Read More »
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TSB #9943
INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT Read More »
POWER TRAIN:MANUAL TRANSMISSION
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TSB #02138
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 BEFORE 12/1/2001. Read More »
POWER TRAIN:AUTOMATIC TRANSMISSION
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TSB #0015
INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS Read More »
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TSB #99152
INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT Read More »
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TSB #9888
INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC Read More »
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TSB #983080
INFORMATION REGARDING TRANSFER CASE REAR HOUSING AND DRIVESHAFT REPLACEMENT. *TT Read More »
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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 Read More »
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TSB #97511
FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD Read More »
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TSB #BC5191961001
FOR CONCERNS OF STALLING, REFLASH PCM W/ 1996 CALIBRATION (R11 LEVEL). *TT Read More »
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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. Read More »
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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 ... Read More »
POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES
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TSB #03148
NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT Read More »
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TSB #002310
SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT Read More »
POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER
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TSB #962612
TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW Read More »
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TSB #96249
TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW Read More »
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
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TSB #01181
BRAKE SHIFT INTERLOCK.*JB Read More »
POWER TRAIN:AXLE ASSEMBLY
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TSB #98233
CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES. *YC Read More »
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TSB #BC2431970501
AEROSTAR E4WD MODELS MAY EXPERIENCE FRONT AXLE LUBRICANT LEAKAGE FROM THE VENT TUBE UNDER SOME DRIVING CONDITIONS. *TW Read More »
ELECTRICAL SYSTEM
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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 Read More »
ELECTRICAL SYSTEM:STARTER ASSEMBLY
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TSB #97111097234
VEHICLES EXHIBITING A "SQUEAKING" OR "CHIRPING" FROM THE BLOWER MOTOR AT LOW BLOWER MOTOR SPEEDS. *YC Read More »
ELECTRICAL SYSTEM:WIRING
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TSB #99222
SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT Read More »
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TSB #96246
WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW Read More »
ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS
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TSB #BC0191970201
VEHICLE ELECTRICAL SYSTEM, SEVERAL MEGAFUSES ARE USED. NOW HAS A NEW PLASTIC COVER. *JD Read More »
ELECTRICAL SYSTEM:IGNITION
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TSB #BC031A597020
MISFIRE CODES P0300-P0306. *TW Read More »
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TSB #BC0315972301
MISFIRE CODES P0300-P0306- REPROGRAMMING PROCEDURES DO NOT APPLY TO AEROSTAR3.0L CALIBRATIONS. *JD Read More »
ELECTRICAL SYSTEM:IGNITION:MODULE
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TSB #9943
INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT Read More »
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TSB #962511
POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP. *TW Read More »
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TSB #BC0313961101
CHECK ENGINE LIGHT, CODE P030X, WITH NO DRIVEABILITY COMPLAINT. *TW Read More »
EXTERIOR LIGHTING:BRAKE LIGHTS
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TSB #99139
CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK. *TT Read More »
EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
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TSB #02176
LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ Read More »
VISIBILITY:WINDSHIELD
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TSB #BC3234970211
WINDSHIELD CRACKS. *TW Read More »
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TSB #96221
WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW Read More »
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM
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TSB #BC2394970501
THE AIR OPERATED COOLING FAN MAYU RUN CONTINUOUSLY IF THE ENGINE ECM FAN CONTROL PARAMETERS ARE SET INCORRECTLY. *TW Read More »
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE
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TSB #01156
SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC Read More »
STRUCTURE
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TSB #9747
FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD Read More »
STRUCTURE:BODY
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TSB #982323
INFORMATION REGARDING REPLACEMENT AND / OR REPAIRS ON ANY LOCK COMPONENT. *YC Read More »
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TSB #BC0344961127
1996-1997 AEROSTAR INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES. *TW Read More »
STRUCTURE:BODY:BUMPERS
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TSB #9832
FRONT AND REAR BUMPERS MADE OF XENOY PLASTIC HAVE HAD THE CONDUCTIVE PRIMER REMOVED FROM SERVICE PARTS. *YC Read More »
STRUCTURE:BODY:DOOR
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TSB #99242
INFORMATION ON REPLACING AND / OR REPAIRING MALFUNCTIONING (DOOR, IGNITION AND DECKLID) LOCKS. *TT Read More »
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TSB #99-8-15
SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP. *TT Read More »
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TSB #98163
LOCKS FAILED. YD Read More »
LATCHES/LOCKS/LINKAGES:DOORS:LATCH
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TSB #962616
SLIDING DOOR - DAMAGED OR MISADJUSTED LATCH MECHANISM. *TW Read More »
VEHICLE SPEED CONTROL:LINKAGES
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TSB #99235
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. Read More »
VEHICLE SPEED CONTROL:CRUISE CONTROL
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TSB #96223
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 AIR CONTROL (IAC) VALVE. Read More »
TIRES
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TSB #9852
INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC Read More »
SEATS
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TSB #BC0344972301
INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES. *JD Read More »
EQUIPMENT:ELECTRICAL
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TSB #BC9688961001
INFORMATION FOR WHEN DIAGNOSING CONCERNS W/ FACTORY INSTALLED CELLULAR PHONES. *TT Read More »
EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
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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 Read More »
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TSB #9873
EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT Read More »
EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES
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TSB #985A12
RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT Read More »
EQUIPMENT:APPLIANCE:AIR CONDITIONER
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TSB #99196
INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT Read More »
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TSB #9735
AIR CONDITIONING- R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE O-RING SPRING LOCK COUPLERS- SERVICE TIP. *JD Read More »
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TSB #96226
AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL. *TW Read More »
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TSB #BC0766961016
CONCERNS OF A/C GOING TO DEFROST MODE WHEN CLIMBING GRADES OR ACCELERATING ARE LIKELY CAUSED BY VACUUM LEAKS. *TT Read More »
UNKNOWN OR OTHER
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TSB #01157
INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC Read More »
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TSB #8164
INFORMATION REGARDING PUMP ALIGNMENT TOOLS. **MR Read More »
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TSB #991210
FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS. *TT Read More »
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TSB #BC2436970501
3.0L VEHICLES SETTING MISFIRE CODES P0300-P0306 SHOULD BE SERVICED USING NORMAL DIAGNOSTICS. *TW Read More »
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TSB #9768
FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD Read More »
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TSB #96E58
RECALL 96E58 - LOW VOLUME RECALL - 229 VEHICLES INVOLVED - REISSUE OF RECALL DOCUMENTATION TO DEALERS. *TW Read More »