1997 Ford Aerostar TSBs
107 Aerostar Technical Service Bulletins
Technical Service Bulletins, or TSBs for short, are notifications made directly by Ford to help automotive technicians diagnose and repair commonly reported Aerostar problems. Interested in how this information is collected? Read more about TSBs.
Recent 1997 Aerostar TSBs
SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE LIGHT
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Description: LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
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Description: INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT. *TT
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Description: THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS. *TT
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Description: SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS. *YC
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Description: BRAKES - BRAKE SERVICE - SERVICE TIPS. *TW
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Description: BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP. *TW
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
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Description: HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE. *YC
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Description: SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *TT
SERVICE BRAKES, HYDRAULIC:ANTILOCK:ABS WARNING LIGHT
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Description: ENGINEERING IS INVESTIGATING CONDITIONS THAT CAUSE THE ABS LIGHT (RABS) TO ILLUMINATE. *TW
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Description: ENGINEERING IS INVESTIGATING CONCERNS OF THE REAR ABS LIGHT COMING ON WHEN THE IGNITION IS IN THE ON POSITION.
SERVICE BRAKES, AIR:DISC:ROTOR
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Description: AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *YC
ENGINE AND ENGINE COOLING:ENGINE
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Description: ENGINE-GEAR DRIVEN SYNCHRONIZERS-INCORRECT INSTALLATION-CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION. *MJ
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Description: 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
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Description: 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
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Description: SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR ALIGNMENT TOOL FOR VEHICLES WITH VARIOUS ENGINE SIZES. *TT
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Description: INFORMATION REGARDING CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART. *MJS
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Description: INFORMATION ON SERVICING OIL PAN GASKET LEAKS. *TT
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Description: BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS. *JD
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Description: FD 1460 ENGINES - NON-FUNCTIONING AIR INTAKE HEATERS - ENSURE THAT THE DIAGNOSTIC SWITCH IS IN OFF POSITION. *TW
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Description: COLD ENGINE KNOCK/TICK NOISE. *JD
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Description: 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
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
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Description: ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT
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Description: 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
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Description: SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT
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Description: SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT
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Description: SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT
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Description: FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT
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Description: COLD ENGINE KNOCK/TICK NOISE. *TW
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
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Description: FUEL INJECTION PUMP- BOSCH- SERVICE INFORMATION FOR FD1060/1460 DIESEL ENGINES. *JD
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Description: SOME 4.0L ENGINES WITH BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK. *JD
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Description: BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK. *JD
ENGINE AND ENGINE COOLING:COOLING SYSTEM
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Description: EXPERIENCING A "THUMPING" NOISE OR TEMPEATURE GAUGE FLUCTATION WITH SOME VEHICLES. *YC
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE
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Description: 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
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Description: 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
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
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Description: INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT
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Description: INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED PARTS. *TW
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Description: INSTRUCTIONS FOR REPLACING DIAGNOSED FAILED COMPONENT. *TW
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Description: DIAGNOSTIC INSTRUCTIONS FOR SERVICING EVAPORATIVE EMISSION PURGE FLOW SYSTEM. *TW
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
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Description: MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK
FUEL SYSTEM, GASOLINE:CARBURETOR SYSTEM
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Description: MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP. *TW
POWER TRAIN
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Description: 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
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Description: 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
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Description: INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT
POWER TRAIN:CLUTCH ASSEMBLY
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Description: UPDATE INFORMATION FOR 1997 4R44E AND 5R55E TRANSMISSIONS - THERE ARE TWO (2) DIFFERENT SIZE DIRECT CLUTCH STEEL PLATES WHEN SERVICING 4R44E OR 5R55E TRANSMISSIONS. *TW
POWER TRAIN:MANUAL TRANSMISSION
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Description: 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. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION
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Description: INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS
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Description: INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT
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Description: ISSUES REGAREDING DIAGNOSTIC TROUBLE CODES ( DTCS ) P0705, P0708, P1704, AND / OR P1705 MAY BE STORED IN MEMORY. *YC
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Description: INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC
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Description: INFORMATION REGARDING TRANSFER CASE REAR HOUSING AND DRIVESHAFT REPLACEMENT. *TT
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Description: SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED. *TT
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Description: SERVICING TIP - TRANSMISSION - THERE ARE TWO DIFFERENT SIZE DIRECT CLUTCH STEEL PLATES WHEN SERVICING 4R44E OR 5R55E TRANSMISSIONS. *TW
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Description: FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD
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Description: TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP. *TW
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Description: FLUID - NEW MERCON V REQUIRED - TRANSMISSION - 4R44E - DESCRIPTION OF FEATURES AND MAJOR COMPONENTS. *TW
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM, PCM)
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Description: GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES
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Description: NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT
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Description: SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER
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Description: TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW
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Description: TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START SWITCH
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Description: BRAKE SHIFT INTERLOCK.*JB
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Description: AS OF 1/7/97 THE AUTOMATIC SHIFT LOCK FEATURE TAG THAT WAS AFFIXED AROUND THE GEAR SELECTOR, HAS BEEN DISCONTINUED FOR PRODUTION. *JD
POWER TRAIN:DRIVELINE
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Description: CONCERNS WITH A WHISTLING OR HISSING NOISE FROM THE MAIN CONTROL AREA OCCURING WHILE IDLING IN DRIVE AND / OR REVERSE ON SOME VEHICLES. *TT
POWER TRAIN:AXLE ASSEMBLY
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Description: CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES. *YC
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Description: AEROSTAR E4WD MODELS MAY EXPERIENCE FRONT AXLE LUBRICANT LEAKAGE FROM THE VENT TUBE UNDER SOME DRIVING CONDITIONS. *TW
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Description: SOME VEHICLES EQUIPPED W/ AN AX4S TRANSAXLE MAY HAVE BEEN SHIPPED W/ A LOW TRANSAXLE FLUID LEVEL. *TT
ELECTRICAL SYSTEM
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Description: FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC
ELECTRICAL SYSTEM:BATTERY
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Description: BATTERY- DISCHARGED- VEHICLES BUILT THROUGH 2/14/97. *JD
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Description: DISCHARGED BATTERIES MAY BE CAUSED BY INTERMITTENT ELECTRICAL DRAW DIFFICULT TO DUPLICATE. *TW
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Description: DISCHARGED BATTERIES ON 97 AEROSTARS MAY BE CAUSED BY AN INTERMITTENT ELECTRICAL DRAW THAT MAY BE DIFFICULT T DUPLICATE. *JD
ELECTRICAL SYSTEM:STARTER ASSEMBLY
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Description: VEHICLES EXHIBITING A "SQUEAKING" OR "CHIRPING" FROM THE BLOWER MOTOR AT LOW BLOWER MOTOR SPEEDS. *YC
ELECTRICAL SYSTEM:WIRING
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Description: SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT
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Description: WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW
ELECTRICAL SYSTEM:FUSES AND CIRCUIT BREAKERS
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Description: VEHICLE ELECTRICAL SYSTEM, SEVERAL MEGAFUSES ARE USED. NOW HAS A NEW PLASTIC COVER. *JD
ELECTRICAL SYSTEM:IGNITION:MODULE
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Description: ENGINES MAY EXHIBIT A DRIVEABILITY CONCERN DESCRIBED AS A SURGE/BUCK/JERK OR HESITATION. *TW
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Description: POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP. *TW
EXTERIOR LIGHTING:BRAKE LIGHTS
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Description: CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK. *TT
VISIBILITY:WINDSHIELD
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Description: WINDSHIELD CRACKS. *TW
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Description: WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM
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Description: THE AIR OPERATED COOLING FAN MAYU RUN CONTINUOUSLY IF THE ENGINE ECM FAN CONTROL PARAMETERS ARE SET INCORRECTLY. *TW
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:HEATER CORE
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Description: SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC
STRUCTURE
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Description: FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD
STRUCTURE:BODY
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Description: INFORMATION REGARDING REPLACEMENT AND / OR REPAIRS ON ANY LOCK COMPONENT. *YC
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Description: SOME DIFFICULTY IN MATCHING THE TEXTURE OF THE OEM ANTI-CHIP STONE ABRASION MATERIAL TO RPAIR MATERIALS WHEN SERVICING. *YC
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Description: SERVICE TIPS FOR SURFACE DEFECT REMOVAL WITHOUT REPAINTING. *YC
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Description: REPAIRS TO VINYL COVERED SURFACES. *YC
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Description: 1996-1997 AEROSTAR INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES. *TW
STRUCTURE:BODY:BUMPERS
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Description: FRONT AND REAR BUMPERS MADE OF XENOY PLASTIC HAVE HAD THE CONDUCTIVE PRIMER REMOVED FROM SERVICE PARTS. *YC
STRUCTURE:BODY:DOOR
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Description: INFORMATION ON REPLACING AND / OR REPAIRING MALFUNCTIONING (DOOR, IGNITION AND DECKLID) LOCKS. *TT
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Description: SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP. *TT
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Description: LOCKS FAILED. YD
VEHICLE SPEED CONTROL:LINKAGES
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Description: 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. THE PCV FITTING IN THE UPPER INTAKE MANIFOLD MAY FREEZE OR
VEHICLE SPEED CONTROL:CRUISE CONTROL
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Description: A ROUGH IDLE, STALLING AT AN IDLE AND/OR DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0174, AND/OR P1151 MAY BE STORED IN MEMORY ON SOME VEHICLES WITH A 4.OL ENGINE. *YC
TIRES
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Description: INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC
SEATS
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Description: INTERIOR TRIM PANELS ARE OCCASIONALLY BEING REPORTED WITH ISSUES OF DAMAGE/DELAMINATION/HOLES. *JD
EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
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Description: 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
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Description: EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT
EQUIPMENT:ELECTRICAL:AIR CONDITIONER
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Description: INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT
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Description: AIR CONDITIONING- R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE O-RING SPRING LOCK COUPLERS- SERVICE TIP. *JD
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Description: AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL. *TW
UNKNOWN OR OTHER
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Description: INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC
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Description: INFORMATION REGARDING PUMP ALIGNMENT TOOLS. **MR
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Description: FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS. *TT
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Description: SOME VINYL COVERED ITEMS SUCH AS DASH PANELS, DOOR TRIM PANELS, CONSOLES, ETC., MAY EXHIBIT A SMALL DENT, SCUFF, ABRASION AND/ OR DISCOLORATION RESULTING FROM ASSEMBLY, TRANSIT, DEALER PREP AND/OR CUSTOMER USAGE. *YC
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Description: FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD
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Description: THE VEHICLE WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSTION. *JD
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Description: THE VEHICLES WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSITION. *JD