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Ford Aerostar Repair Manuals

Ford AerostarFree Ford Aerostar repair manuals [pdf] for do-it-yourselfers. Content: general information; maintenance; common specs & procedures; DTC index (trouble codes); accessories & equipment; body & frame; brakes; driveline/axles; electrical; wiring diagrams; engine; engine performance; HVAC; lighting; restraints; steering; suspension; transmission.

The 1st generation Ford Aerostar was introduced in 1986 in a single body length as a cargo van and a 7-passenger van (two trim levels were available: base-trim XL and deluxe-trim XLT). The standard engine was the 2.3 L Lima SOHC I4 produced 100 hp (75 kW) and 135 lb·ft (183 N·m) while the 2.8 L Cologne OHV V6 produced 115 hp (86 kW) was an option. In 1987, the 2.8L Cologne engine was replaced with the 3.0 L Vulcan OHV V6 produced 145 hp (108 kW) and 170 lb·ft (230N·m). In 1990, the 4.0 L Cologne OHV V6 produced 160 hp (119 kW) and 225 lb·ft (305 N·m) became an option for all non-XL models.
The 2nd generation Ford Aerostar was introduced in 1992 in van and wagon body styles in two lengths, the wagon was available in three trims (XL, XLT, and Eddie Bauer). Two petrol engines were available: 3.0 L Vulcan OHV V6 produced 145 hp (108 kW) and 170 lb·ft (230N·m), 4.0 L Cologne OHV V6 produced 160 hp (119 kW) and 225 lb·ft (305 N·m). In 1997, the 4.0L Cologne got paired with a 5-speed automatic transmission. From 1994 to 1996 the Sport option package was available for any non-Eddie Bauer wagon. This was a cosmetic upgrade only, the 3.0L Vulcan was still under the hood of XL versions with this option.
Ford Aerostar technical specs:
Class: minivan
Body style: 4-door passenger van, 4-door cargo van
Layout: front engine, rear-wheel drive and all-wheel drive
Wheelbase: 118.9 in (3,020 mm)
Length: 174.9-190.3 in (4,442 mm)
Width: 71.7 in (1,821 mm)
Height: 72.2 in (1,834 mm) – 74.0 in (1,880 mm)
Engines: 2.3L Lima I4; 2.8L Cologne V6; 3.0L Vulcan V6; 4.0L Cologne V6
Transmissions: 4-speed A4LD automatic; 5-speed TK5 Toyo-Kogyo manual; 5-speed M5OD manual
Years: 1986, 1987, 1988, 1989, 1990, 1991
Class: minivan
Body style: 4-door passenger van, 4-door cargo van
Layout: front engine, rear-wheel drive; front engine, all-wheel drive
Wheelbase: 118.9 in (3,020 mm)
Length: 174.9-190.3 in (4,442-4,834 mm)
Width: 71.7 in (1,821 mm)
Height: 72.2-74.0 in (1,834-1,880 mm)
Engines: 3.0L Vulcan OHV V6 145 hp (108 kW) 1992-1997; 4.0L Cologne OHV V6 160 hp (119 kW) 1992-1997
Transmissions: 4-speed A4LD automatic; 4-speed 4R44E automatic; 4-speed 4R55E automatic; 5-speed 5R55E automatic; 5-speed M5OD manual
Years: 1992, 1993, 1994, 1995, 1996, 1997
Free Ford repair manuals
Free Ford repair manuals