1996 Ford Aerostar Scheduled Maintenance Guide 1st Printing

1996 Ford Aerostar Manual

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  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 1
    General Information 1
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 2
    Table of Contents General Maintenance Information ...3 What Maintenance Schedule Do You Follow? ...6 Normal Schedule...7 Severe Duty Schedule ...24 Owner Maintenance Checks ...50 2
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 3
    performance of your Ford Motor Company vehicle. We recommend that you also perform the Owner Maintenance Checks listed. These services are matters of day-to-day care that are also important to the proper operation of your vehicle. The recommended lubricants, fluids and service parts conforming to
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 4
    other than Ford or Motorcraft parts or Ford authorized remanufactured parts are used for maintenance replacements or for the service of components affecting emission control, such non-Ford parts should be equivalent to genuine Ford Motor Company parts in performance and durability. It is the owner
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 5
    operation. Proper torque specifications are provided in your Owner Guide. Also retighten to proper torque specification at 500 miles/800 km after (1) any wheel change or (2) any other time the wheel lug nuts have been loosened. PRE-DELIVERY CHECK u Pre-Delivery Service Inspection Completed 5
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 6
    Maintenance Schedule Do You Follow? Normal Schedule Follow the Normal Schedule for most normal everyday driving conditions. Severe Duty Schedule Follow the Severe Duty Schedule . u Extensive idling, such as police, taxi or door-to-door delivery service. u Snowplowing u Short trips of less than 10
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 7
    Control Service are shown in this type and style. For items marked with number in parentheses such as (1), see footnote at end of this section. Regular Maintenance Intervals for the Normal Schedule 5,000 MILES (8,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 8
    engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (24,000 km) or 12 months. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 9
    by exhaust system shielding. NOTE: It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler. 20,000 MILES (32,000 Kilometers) u Change engine oil and replace oil filter
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 10
    filter. (2) u Replace fuel filter (Recommended but not required for California vehicles). u Change automatic transmission fluid. u Inspect disc brake system, lubricate caliper slide rails. u Inspect drum brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2 vehicles
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 11
    , arms, springs and rear jounce bumpers for wear or damage. 35,000 MILES (56,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 12
    engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (24,000 km) or 12 months. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 13
    shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). loose parts. Remove any foreign material trapped by exhaust system shielding. u Inspect exhaust system for leaks, damage or Normal Schedule 13
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 14
    u Replace PCV valve. (3) u Replace fuel filter (Recommended but not required for California vehicles). u Change automatic transmission fluid. u Inspect disc brake system, lubricate caliper slide rails. u Inspect drum brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 15
    (E-4WD vehicles only). u Replace all front axle and transfer case lube 65,000 MILES (104,000 Kilometers) u Change engine oil and replace oil filter. u Inspect and lubricate automatic transmission shift linkage. u Rotate tires and adjust air pressure. (1) u Lubricate steering linkage suspension
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 16
    engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (24,000 km) or 12 months. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 17
    drum brake systems, hoses and lines. 80,000 MILES (128,000 Kilometers) u Change engine oil and replace oil filter. u Change coolant every 30,000 miles (48,000 36 months. km) or 85,000 MILES (136,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air pressure
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 18
    accessory drive belt(s). u Replace fuel filter (Recommended but not required for California vehicles). u Change automatic transmission fluid. u Inspect disc brake system, lubricate caliper slide rails. u Inspect drum brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 19
    . u Inspect parking brake system for damage and operation. 95,000 MILES (152,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 20
    engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (24,000 km) or 12 months. u Rotate tires and adjust air pressure. (1) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 21
    Inspect drum brake systems, hoses and lines. 110,000 MILES (176,000 Kilometers) u Change engine oil and replace oil filter. u Change coolant every 30,000 miles (48,000 36 months. km) or 115,000 MILES (184,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 22
    . u Replace PCV valve. u Replace fuel filter (Recommended but not required for California vehicles). u Change automatic transmission fluid. u Inspect disc brake system, lubricate caliper slide rails. u Inspect drum brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 23
    at 500 miles/800 km of new vehicle operation (100 miles/160 km and 500 miles/800 km for vehicles equipped with dual rear wheels or equipped for snowplowing). Proper torque specifications are provided in your Owner Guide. Also retighten to proper torque specification at 500 miles/800 km after (1) any
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 24
    dust conditions. However, the conditions you drive in may require even more frequent air cleaner replacement intervals than those shown. Check with your dealer. Maintenance Intervals for Severe Duty Schedule 3,000 MILES (5,000 Kilometers) u Change engine oil and replace oil filter. 24 Severe Duty
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    exhaust system for leaks, damage or NOTE: It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler. 9,000 MILES (15,000 Kilometers) u Change engine oil and replace oil
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 26
    (25,000 Kilometers) u Change engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. u Rotate tires and adjust air pressure. (3)(4) u Inspect disc brake system and lubricate caliper slide rails
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 27
    oil and replace oil filter. u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 28
    transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system shielding. u Inspect exhaust system for leaks, damage or NOTE
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 29
    Replace fuel filter (Recommended but not required u Inspect and lubricate automatic transmission u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 30
    front wheel bearings (4x2 vehicles only). operation. u Inspect parking brake system for damage and 33,000 MILES (55,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air pressure. (3)(4) 36,000 MILES (60,000 Kilometers) u Change engine oil and replace oil
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 31
    u Change engine oil and replace oil filter. 42,000 MILES (70,000 Kilometers) u Change engine oil and replace oil filter. u Change automatic transmission fluid. u Rotate tires and adjust air pressure. (3)(4) u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 32
    engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. caliper slide rails. (2) u Inspect disc brake system and lubricate u Inspect drum brake systems, hoses and lines. 32 Severe Duty Schedule
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 33
    lubricate automatic transmission u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system shielding. u Inspect exhaust system for leaks, damage or NOTE
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 34
    oil and replace oil filter. u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 35
    engine oil and replace oil filter. u Replace spark plugs. u Inspect accessory drive belt(s). u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. u Replace air cleaner filter. (1) u Replace PCV valve. (5) u Replace fuel filter
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 36
    brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2 vehicles only). operation. u Inspect parking brake system for damage and 63,000 MILES (105,000 Kilometers) u Change engine oil and replace oil filter. u Change automatic transmission fluid. 36 Severe Duty Schedule
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 37
    oil and replace oil filter. u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 38
    oil and replace oil filter. u Inspect and lubricate automatic transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 39
    Kilometers) u Change engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. caliper slide rails. (2) u Inspect disc brake system and lubricate u Inspect drum brake systems, hoses and lines. 78
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 40
    linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system shielding. u Inspect exhaust system for leaks, damage or 40 Severe Duty Schedule
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 41
    Change engine oil and replace oil filter. u Rotate tires and adjust air pressure. (3)(4) 90,000 MILES (150,000 Kilometers) u Change engine oil and replace oil filter. u Inspect accessory drive belt(s). u Replace air cleaner filter. (1) u Inspect engine cooling system, hoses, and clamps; and check
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 42
    lubricate front wheel bearings (4x2 vehicles only). operation. u Inspect parking brake system for damage and 93,000 MILES (155,000 Kilometers) u Change engine oil and replace oil filter. 96,000 MILES (160,000 Kilometers) u Change engine oil and replace oil filter. u Rotate tires and adjust air
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 43
    around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler. u Lubricate throttle kickdown or TV lever ball studs. 99,000 MILES (165,000 Kilometers) u Change engine oil and replace oil filter. u Replace rear axle lube. Severe Duty Schedule 43
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 44
    175,000 Kilometers) u Change engine oil and replace oil filter. u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. u Change automatic transmission fluid. u Rotate tires and adjust air pressure. (3)(4) 44 Severe Duty Schedule
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    u Inspect drum brake systems, hoses and lines. 108,000 MILES (180,000 Kilometers) u Change engine oil and replace oil filter. u Change engine coolant every 30,000 miles (50,000 km) or 36 months. shift linkage. u Inspect and lubricate automatic transmission u Lubricate steering linkage suspension
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 46
    transmission shift linkage. u Lubricate steering linkage suspension, driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped). (2) loose parts. Remove any foreign material trapped by exhaust system shielding. u Inspect exhaust system for leaks, damage or NOTE
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 47
    engine oil and replace oil filter. u Replace spark plugs. u Inspect accessory drive belt(s). u Inspect engine cooling system, hoses, and clamps; and check coolant strength every 15,000 miles (25,000 km) or 12 months. u Replace air cleaner filter. (1) u Replace PCV valve. u Replace fuel filter
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 48
    rails. (2) u Inspect drum brake systems, hoses and lines. u Inspect and lubricate front wheel bearings (4x2 vehicles only). operation. u Inspect parking brake system for damage and (1) Extremely dusty conditions will require more frequent replacement of your air filter. Check your air filter at
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 49
    at 500 miles/800 km of new vehicle operation (100 miles/160 km and 500 miles/800 km for vehicles equipped with dual rear wheels or equipped for snowplowing). Proper torque specifications are provided in your Owner Guide. Also retighten to proper torque specification at 500 miles/800 km after (1) any
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 50
    your dealer or qualified service technician for service advice as soon as possible. These Owner Maintenance Checks are generally not covered by warranties and you may be charged for labor, parts and lubricants used. When You Stop for Fuel: u Check the engine oil level. u Check the windshield washer
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 51
    dampened with washer fluid. hoses for leaks or damage. nuts. u Check radiator, heater and air-conditioning u Check for worn tires and loose wheel lug u Clean body and door drain holes. u Flush complete underside of vehicle. u Inspect underbody components for damage. Owner Maintenance Checks 51
  • 1996 Ford Aerostar | Scheduled Maintenance Guide 1st Printing - Page 52
    door rubber weatherstrips. u Clean battery and terminals, check electrolyte level on low maintenance (auxiliary and replacement) batteries. If any of these conditions are noted, bring them to the attention of your dealer or qualified service technician as soon as possible. 52 Owner Maintenance
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General Information