1997 Ford Aerostar
108 Technical Service Bulletins (TSBs)
TSB List for the 1997 Ford Aerostar
Technical Service Bulletins (TSBs) for the 1997 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.
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: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:ABS WARNING LIGHT
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TSB #BC2232970501
ENGINEERING IS INVESTIGATING CONDITIONS THAT CAUSE THE ABS LIGHT (RABS) TO ILLUMINATE. *TW Read More »
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TSB #97050110607
ENGINEERING IS INVESTIGATING CONCERNS OF THE REAR ABS LIGHT COMING ON WHEN THE IGNITION IS IN THE ON POSITION. 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 #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 #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 »
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TSB #BC3491972301
SOME 4.0L ENGINES WITH BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK. *JD Read More »
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TSB #BC1018997230
BLOCK HEATERS MAY EXPERIENCE COOLANT LEAKS DUE TO INTERFERENCE WITH THE BLOCK. *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 »
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 #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:CLUTCH ASSEMBLY
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TSB #BC105979705
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 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 #982312
ISSUES REGAREDING DIAGNOSTIC TROUBLE CODES ( DTCS ) P0705, P0708, P1704, AND / OR P1705 MAY BE STORED IN MEMORY. *YC 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 #BC2226970501
SERVICING TIP - TRANSMISSION - THERE ARE TWO DIFFERENT SIZE DIRECT CLUTCH STEEL PLATES WHEN SERVICING 4R44E OR 5R55E TRANSMISSIONS. *TW Read More »
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TSB #97511
FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD Read More »
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TSB #962410
TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP. *TW Read More »
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TSB #962215
FLUID - NEW MERCON V REQUIRED - TRANSMISSION - 4R44E - DESCRIPTION OF FEATURES AND MAJOR COMPONENTS. *TW Read More »
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)
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TSB #042107
GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT 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 »
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TSB #BC3441972301
AS OF 1/7/97 THE AUTOMATIC SHIFT LOCK FEATURE TAG THAT WAS AFFIXED AROUND THE GEAR SELECTOR, HAS BEEN DISCONTINUED FOR PRODUTION. *JD Read More »
POWER TRAIN:DRIVELINE
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TSB #98514
CONCERNS WITH A WHISTLING OR HISSING NOISE FROM THE MAIN CONTROL AREA OCCURING WHILE IDLING IN DRIVE AND / OR REVERSE ON SOME VEHICLES. *TT 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 »
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TSB #BC5197961001
SOME VEHICLES EQUIPPED W/ AN AX4S TRANSAXLE MAY HAVE BEEN SHIPPED W/ A LOW TRANSAXLE FLUID LEVEL. *TT 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:12V/24V/48V BATTERY
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TSB #97623
BATTERY- DISCHARGED- VEHICLES BUILT THROUGH 2/14/97. *JD Read More »
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TSB #BC3301970204
DISCHARGED BATTERIES MAY BE CAUSED BY INTERMITTENT ELECTRICAL DRAW DIFFICULT TO DUPLICATE. *TW Read More »
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TSB #BC1028597020
DISCHARGED BATTERIES ON 97 AEROSTARS MAY BE CAUSED BY AN INTERMITTENT ELECTRICAL DRAW THAT MAY BE DIFFICULT T DUPLICATE. *JD 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:MODULE
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TSB #9943
INFORMATION REGARDING REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS). *TT Read More »
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TSB #BC2433970501
ENGINES MAY EXHIBIT A DRIVEABILITY CONCERN DESCRIBED AS A SURGE/BUCK/JERK OR HESITATION. *TW Read More »
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TSB #962511
POWERTRAIN CONTROL MODULE -REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP. *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 #9844
SOME DIFFICULTY IN MATCHING THE TEXTURE OF THE OEM ANTI-CHIP STONE ABRASION MATERIAL TO RPAIR MATERIALS WHEN SERVICING. *YC Read More »
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TSB #9831
REPAIRS TO VINYL COVERED SURFACES. *YC Read More »
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TSB #9833
SERVICE TIPS FOR SURFACE DEFECT REMOVAL WITHOUT REPAINTING. *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 »
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 #9868
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 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: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: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 »
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 #98259
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. Read More »
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TSB #9768
FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD Read More »
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TSB #BC3483972301
THE VEHICLE WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSTION. *JD Read More »
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TSB #BC1019797230
THE VEHICLES WILL SHIFT 1,2,3,4,5 REGARDLESS OF THROTTLE POSITION. *JD Read More »