1996 FORD AEROSTAR Recalls (6)

Campaign:
96V070000 on 04/23/1996
Component:
Latches/locks/linkages:doors:latch
Manufactured:
01/31/1996 - 02/29/1996
Affected:
73,500
Defect:
When in the secondary latched position, the driver door latches may open when subjected to transverse loads less than that specified in fmvss no. 206, "door locks and door retention components."
Consequence:
The driver's door, when closed only to the secondary latched position, may not sustain a 1,000 pound transverse load.
Correction:
Dealers will inspect and, if necessary, replace the driver door latch.
Notes:
Vehicle description: passenger, multi-purpose vehicles and mini-vans.note: owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time, should contact ford at 1-800-392-3673. also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:
96V161000 on 09/02/1996
Component:
Equipment:other:labels
Manufactured:
12/14/1995 - 03/10/1996
Affected:
134,770
Defect:
The certification labels on the involved vehicles has incorrect rear tire inflation pressure designations. this does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."
Consequence:
Incorrect inflation pressures could cause premature wear of the rear tires. .
Correction:
Owners will be provided with correct certification labels and instructions for installing these labels. dealers can install this label if the owner so desires.
Notes:
Owner notification:owner notification is expected to begin october 18, 1996. note:owners who do not receive the correct label within a reasonable time free of charge should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:
97V204000 on 11/19/1997
Component:
Power train:transfer case (4-wheel drive)
Manufactured:
01/30/1992 - 01/19/1997
Affected:
75,000
Defect:
Vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.
Consequence:
This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Correction:
Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Notes:
Owner notification is expected to begin february 16,1998.owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.
Campaign:
98E010000 on 04/08/1998
Component:
Service brakes, air:disc:rotor
Affected:
23,500
Defect:
Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Consequence:
Loss of braking can result.
Correction:
Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Notes:
Owner notification is expected to begin during april 1998.owners who do not receive the free rotors within a reasonable time should contact aimco at 815-759-7935.also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
Campaign:
99V029000 on 02/15/1999
Component:
Electrical system:ignition:switch
Manufactured:
08/11/1991 - 08/21/1997
Affected:
762,201
Defect:
Vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Consequence:
This can cause over heating and the potential for a vehicle fire.
Correction:
Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Notes:
Owner notification began march 19, 1999.owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contactford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
Campaign:
06E022000 on 03/12/2006
Component:
Service brakes, hydraulic
Affected:
7,440
Defect:
Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Consequence:
Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Correction:
Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.
Notes:
This recall only pertains to aftermarket napa, raybestos, ac delco, aimco, carquest, and bendix brake hydraulic master cylinders and has no relation to any original equipment installed on daimlerchrysler or ford vehicles.customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

1996 FORD AEROSTAR TSBs (104)

Bulletin:
951912
Component:
103000 power train:automatic transmission
Summary:
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 occ
Bulletin:
95212
Component:
036000 service brakes, hydraulic:antilock
Summary:
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. if petroleum-based grease is used to lubricate any par
Bulletin:
BC0766961016
Component:
353600 equipment:air conditioner
Summary:
Concerns of a/c going to defrost mode when climbing grades or accelerating are likely caused by vacuum leaks. *tt
Bulletin:
BC0880961004
Component:
062000 engine and engine cooling:cooling system
Summary:
Lack of cooling due to complete loss of charge. may have a machining defect in the high pressure relief valve. *tt
Bulletin:
BC5191961001
Component:
103000 power train:automatic transmission
Summary:
For concerns of stalling, reflash pcm w/ 1996 calibration (r11 level). *tt
Bulletin:
BC9666961001
Component:
061000 engine and engine cooling:engine
Summary:
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
Bulletin:
BC9688961001
Component:
353000 equipment:electrical
Summary:
Information for when diagnosing concerns w/ factory installed cellular phones. *tt
Bulletin:
BC0313961101
Component:
116200 electrical system:ignition:module
Summary:
Check engine light, code p030x, with no driveability complaint. *tw
Bulletin:
BC0324961101
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Cold engine knock/tick noise. *tw
Bulletin:
BC0344961127
Component:
162000 structure:body
Summary:
1996-1997 aerostar interior trim panels are occasionally being reported with issues of damage/delamination/holes. *tw
Bulletin:
BC0407961115
Component:
063000 engine and engine cooling:exhaust system
Summary:
Instructions for replacing diagnosed failed parts. *tw
Bulletin:
BC0490961112
Component:
063000 engine and engine cooling:exhaust system
Summary:
Instructions for replacing diagnosed failed component. *tw
Bulletin:
BC9714961101
Component:
063000 engine and engine cooling:exhaust system
Summary:
Diagnostic instructions for servicing evaporative emission purge flow system. *tw
Bulletin:
96246
Component:
114000 electrical system:wiring
Summary:
Wiring - electrical diode identification and service replacements. *tw
Bulletin:
96249
Component:
103700 power train:automatic transmission:torque converter
Summary:
Torque converter - leak test procedure - service tip. *tw
Bulletin:
96221
Component:
131000 visibility:windshield
Summary:
Windshield and interior glass - fog/film. *tw
Bulletin:
96222
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Brakes - elimination of sanding rotors and drums - service tip. *tw
Bulletin:
96223
Component:
185000 vehicle speed control:cruise control
Summary:
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. *tw
Bulletin:
96225
Component:
075000 fuel system, gasoline:carburetor system
Summary:
Mass air flow sensor - replacement as an assembly - service tip. *tw
Bulletin:
96226
Component:
353600 equipment:air conditioner
Summary:
Air conditioning - compressor failure - insufficient amount of refrigerant oil. *tw
Bulletin:
962511
Component:
116200 electrical system:ignition:module
Summary:
Powertrain control module -reprogram powertrain control module (pcm) - service procedures - service tip. *tw
Bulletin:
962524
Component:
061000 engine and engine cooling:engine
Summary:
Engine - 4.0l - new torque-to-yield connecting rod fasteners. *tw
Bulletin:
962612
Component:
103700 power train:automatic transmission:torque converter
Summary:
Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw
Bulletin:
962616
Component:
171100 latches/locks/linkages:doors:latch
Summary:
Sliding door - damaged or misadjusted latch mechanism. *tw
Bulletin:
962617
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Brakes - brake service - service tips. *tw
Bulletin:
962619
Component:
061000 engine and engine cooling:engine
Summary:
Engine - 4.0l - torque-to-yield (tty) crankshaft damper bolt. *tw
Bulletin:
BC0191970201
Component:
115000 electrical system:fuses and circuit breakers
Summary:
Vehicle electrical system, several megafuses are used. now has a new plastic cover. *jd
Bulletin:
BC0324970201
Component:
061000 engine and engine cooling:engine
Summary:
Cold engine knock/tick noise. *jd
Bulletin:
BC0315972301
Component:
116000 electrical system:ignition
Summary:
Misfire codes p0300-p0306- reprogramming procedures do not apply to aerostar3.0l calibrations. *jd
Bulletin:
BC0344972301
Component:
220000 seats
Summary:
Interior trim panels are occasionally being reported with issues of damage/delamination/holes. *jd
Bulletin:
BC3485972301
Component:
062300 engine and engine cooling:cooling system:hose
Summary:
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
Bulletin:
BC1019997230
Component:
062300 engine and engine cooling:cooling system:hose
Summary:
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
Bulletin:
96E58
Component:
980000 unknown or other
Summary:
Recall 96e58 - low volume recall - 229 vehicles involved - reissue of recall documentation to dealers. *tw
Bulletin:
BC031A597020
Component:
116000 electrical system:ignition
Summary:
Misfire codes p0300-p0306. *tw
Bulletin:
9735
Component:
353600 equipment:air conditioner
Summary:
Air conditioning- r-134a tracer dye installed in a/c system and three o-ring spring lock couplers- service tip. *jd
Bulletin:
9747
Component:
160000 structure
Summary:
Frame- rivet replacement with bolts- service tips. *jd
Bulletin:
BC3234970211
Component:
131000 visibility:windshield
Summary:
Windshield cracks. *tw
Bulletin:
BC3244970210
Component:
061000 engine and engine cooling:engine
Summary:
Fd 1460 engines - non-functioning air intake heaters - ensure that the diagnostic switch is in off position. *tw
Bulletin:
97716
Component:
061200 engine and engine cooling:engine:diesel
Summary:
Fuel injection pump- bosch- service information for fd1060/1460 diesel engines. *jd
Bulletin:
97511
Component:
103000 power train:automatic transmission
Summary:
Fluid- transmission fluid usage charts. *jd
Bulletin:
9768
Component:
980000 unknown or other
Summary:
Fuel economy- customer expectations versus vehicle usage. *jd
Bulletin:
97610
Component:
061000 engine and engine cooling:engine
Summary:
Blower motor- "chirping" or "squeaking" from blower motor at low speeds. *jd
Bulletin:
BC2394970501
Component:
138000 visibility:defroster/defogger system
Summary:
The air operated cooling fan mayu run continuously if the engine ecm fan control parameters are set incorrectly. *tw
Bulletin:
BC2431970501
Component:
106000 power train:axle assembly
Summary:
Aerostar e4wd models may experience front axle lubricant leakage from the vent tube under some driving conditions. *tw
Bulletin:
BC2436970501
Component:
980000 unknown or other
Summary:
3.0l vehicles setting misfire codes p0300-p0306 should be serviced using normal diagnostics. *tw
Bulletin:
97111097234
Component:
113000 electrical system:starter assembly
Summary:
Vehicles exhibiting a "squeaking" or "chirping" from the blower motor at low blower motor speeds. *yc
Bulletin:
97090297189
Component:
062000 engine and engine cooling:cooling system
Summary:
Experiencing a "thumping" noise or tempeature gauge fluctation with some vehicles. *yc
Bulletin:
9832
Component:
162200 structure:body:bumpers
Summary:
Front and rear bumpers made of xenoy plastic have had the conductive primer removed from service parts. *yc
Bulletin:
985A5
Component:
034530 service brakes, hydraulic:foundation components:disc:rotor
Summary:
Hub-mount brake rotor machining equipment from rotunda is now approved for warranty and service use. *yc
Bulletin:
985A11
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Service tip information regarding elimination of sanding rotors and drums. *yc
Bulletin:
985A13
Component:
034500 service brakes, hydraulic:foundation components:disc
Summary:
The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc
Bulletin:
9888
Component:
103000 power train:automatic transmission
Summary:
Information on a new transmission fluid usage chart. *yc
Bulletin:
9845
Component:
045300 service brakes, air:disc:rotor
Summary:
Availability of hub-mount brake rotor machining equipment. *yc
Bulletin:
9852
Component:
190000 tires
Summary:
Information on tire company telephone numbers for customer assistance. *yc
Bulletin:
9864
Component:
063000 engine and engine cooling:exhaust system
Summary:
Information on a buzzing or rattle noise from the exhaust system. *tt
Bulletin:
9873
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio. *tt
Bulletin:
982010
Component:
063000 engine and engine cooling:exhaust system
Summary:
Experiencing a " buzzing " or " rattling " noise from the exhaust system. *yc
Bulletin:
98233
Component:
106000 power train:axle assembly
Summary:
Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles. *yc
Bulletin:
982310
Component:
063100 engine and engine cooling:exhaust system:emission control
Summary:
Mass air flow (maf)- sensor contamination- service tip. *ak
Bulletin:
982323
Component:
162000 structure:body
Summary:
Information regarding replacement and / or repairs on any lock component. *yc
Bulletin:
98246
Component:
110000 electrical system
Summary:
Ford motor company has released a new electrical grease ( f8az - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals. *yc
Bulletin:
9943
Component:
100000 power train
Summary:
Information regarding reprogramming powertrain control modules (pcms). *tt
Bulletin:
5518
Component:
061000 engine and engine cooling:engine
Summary:
Information on servicing oil pan gasket leaks. *tt
Bulletin:
9814
Component:
034530 service brakes, hydraulic:foundation components:disc:rotor
Summary:
Subject regarding the availability of hub-mount brake rotor machining equipment. *tt
Bulletin:
98112
Component:
103000 power train:automatic transmission
Summary:
Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt
Bulletin:
99816
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt
Bulletin:
99129
Component:
353400 equipment:electrical:radio/tape deck/cd etc.
Summary:
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
Bulletin:
99139
Component:
125000 exterior lighting:brake lights
Summary:
Conditions with the brake lamps inadvertently disabling the brake shift interlock. *tt
Bulletin:
983080
Component:
103000 power train:automatic transmission
Summary:
Information regarding transfer case rear housing and driveshaft replacement. *tt
Bulletin:
99222
Component:
114000 electrical system:wiring
Summary:
Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
Bulletin:
99183
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Service tip information on revised oil pan gasket replacement procedure. *tt
Bulletin:
99194
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Information for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement. *tt
Bulletin:
99196
Component:
353600 equipment:air conditioner
Summary:
Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
Bulletin:
99235
Component:
182000 vehicle speed control:linkages
Summary:
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
Bulletin:
99242
Component:
162300 structure:body:door
Summary:
Information on replacing and / or repairing malfunctioning (door, ignition and decklid) locks. *tt
Bulletin:
6997
Component:
061000 engine and engine cooling:engine
Summary:
Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt
Bulletin:
13180
Component:
061000 engine and engine cooling:engine
Summary:
Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs
Bulletin:
98163
Component:
162300 structure:body:door
Summary:
Locks failed. yd
Bulletin:
0015
Component:
103000 power train:automatic transmission
Summary:
Information regarding the new transmission cooler flusher- service tip. *mjs
Bulletin:
985A52
Component:
034000 service brakes, hydraulic:foundation components
Summary:
This bulletin contains service tips when servicing any brake related roughness / pull concerns. *tt
Bulletin:
96719
Component:
010000 steering
Summary:
Experiencing a rapping or clanging noise when the steering wheel is turned rapidly or when turning on a bumpy road surface. *tt
Bulletin:
96726
Component:
103000 power train:automatic transmission
Summary:
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. failure to change over or convert the fluid pan may result in a transmission fluid leak
Bulletin:
985A12
Component:
354600 equipment:mechanical:wrecker and wheel lift devices
Summary:
Recommended guidelines for towing behind recreational vehicles. *tt
Bulletin:
8164
Component:
980000 unknown or other
Summary:
Information regarding pump alignment tools. **mr
Bulletin:
6896
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt
Bulletin:
13118
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt
Bulletin:
99-8-15
Component:
162300 structure:body:door
Summary:
Subject regarding door trim panel replacement - service tip. *tt
Bulletin:
991210
Component:
980000 unknown or other
Summary:
Ford motor company has released a private labeled material to be used for iron particle / acid rain service repairs. *tt
Bulletin:
99152
Component:
103000 power train:automatic transmission
Summary:
Information on the new flush and fill tool available through rotunda. *tt
Bulletin:
002310
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt
Bulletin:
01124
Component:
061000 engine and engine cooling:engine
Summary:
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
Bulletin:
01156
Component:
138120 visibility:defroster/defogger system:windshield:heater core
Summary:
Some vehicles may exhibit heater core leaks. *slc
Bulletin:
01157
Component:
980000 unknown or other
Summary:
Information regarding transmission fluid usage charts. *slc
Bulletin:
01181
Component:
103800 power train:automatic transmission:park/neutral start switch
Summary:
Brake shift interlock.*jb
Bulletin:
01197
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
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
Bulletin:
01246
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Engine oil system priming procedures, service tips for reports of premature engine failure. *tt
Bulletin:
02142
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
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
Bulletin:
02138
Component:
102000 power train:manual transmission
Summary:
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
Bulletin:
15887
Component:
100000 power train
Summary:
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
Bulletin:
0282
Component:
100000 power train
Summary:
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
Bulletin:
870197
Component:
061000 engine and engine cooling:engine
Summary:
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
Bulletin:
03148
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt
Bulletin:
02221
Component:
061000 engine and engine cooling:engine
Summary:
Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj
Bulletin:
02176
Component:
032100 service brakes, hydraulic:switches:brake light
Summary:
Lamp-brake-invadvertent disabling of brake shift interlock. *mj

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