1997 FORD AEROSTAR Recalls (5)

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:
00V425000 on 01/01/2001
Component:
Vehicle speed control:cables
Manufactured:
08/13/1996 - 08/21/1997
Affected:
36,500
Defect:
Vehicle description: minivans equipped with 3.0l engines. an accelerator cable was kinked during installation, causing the core wires to eventually fray.
Consequence:
This could increase the friction in the cable, causing the throttle to be slow to return to idle. this condition could result in a stuck throttle.
Correction:
Dealers will install a new accelerator cable.
Notes:
Owner notification began february 23, 2001.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 1-888-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.

1997 FORD AEROSTAR TSBs (107)

Bulletin:
BC5197961001
Component:
106000 power train:axle assembly
Summary:
Some vehicles equipped w/ an ax4s transaxle may have been shipped w/ a low transaxle fluid 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:
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:
962410
Component:
103000 power train:automatic transmission
Summary:
Transmission - e40d - 4r70w - 4r44e - 5r55e - new digital transmission range sensor - diagnosis 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:
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:
962215
Component:
103000 power train:automatic transmission
Summary:
Fluid - new mercon v required - transmission - 4r44e - description of features and major components. *tw
Bulletin:
962511
Component:
116200 electrical system:ignition:module
Summary:
Powertrain control module -reprogram powertrain control module (pcm) - service procedures - service tip. *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:
962617
Component:
034000 service brakes, hydraulic:foundation components
Summary:
Brakes - brake service - service tips. *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:
BC0344972301
Component:
220000 seats
Summary:
Interior trim panels are occasionally being reported with issues of damage/delamination/holes. *jd
Bulletin:
BC3441972301
Component:
103800 power train:automatic transmission:park/neutral start switch
Summary:
As of 1/7/97 the automatic shift lock feature tag that was affixed around the gear selector, has been discontinued for prodution. *jd
Bulletin:
BC3483972301
Component:
980000 unknown or other
Summary:
The vehicle will shift 1,2,3,4,5 regardless of throttle postion. *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:
BC3491972301
Component:
061200 engine and engine cooling:engine:diesel
Summary:
Some 4.0l engines with block heaters may experience coolant leaks due to interference with the block. *jd
Bulletin:
BC1018997230
Component:
061200 engine and engine cooling:engine:diesel
Summary:
Block heaters may experience coolant leaks due to interference with the block. *jd
Bulletin:
BC1019797230
Component:
980000 unknown or other
Summary:
The vehicles will shift 1,2,3,4,5 regardless of throttle position. *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:
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:
BC1028597020
Component:
111000 electrical system:battery
Summary:
Discharged batteries on 97 aerostars may be caused by an intermittent electrical draw that may be difficult t duplicate. *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:
BC3301970204
Component:
111000 electrical system:battery
Summary:
Discharged batteries may be caused by intermittent electrical draw difficult to duplicate. *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:
97623
Component:
111000 electrical system:battery
Summary:
Battery- discharged- vehicles built through 2/14/97. *jd
Bulletin:
BC2226970501
Component:
103000 power train:automatic transmission
Summary:
Servicing tip - transmission - there are two different size direct clutch steel plates when servicing 4r44e or 5r55e transmissions. *tw
Bulletin:
BC2232970501
Component:
036400 service brakes, hydraulic:antilock:abs warning light
Summary:
Engineering is investigating conditions that cause the abs light (rabs) to illuminate. *tw
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:
BC2433970501
Component:
116200 electrical system:ignition:module
Summary:
Engines may exhibit a driveability concern described as a surge/buck/jerk or hesitation. *tw
Bulletin:
BC105979705
Component:
101000 power train:clutch assembly
Summary:
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
Bulletin:
97050110607
Component:
036400 service brakes, hydraulic:antilock:abs warning light
Summary:
Engineering is investigating concerns of the rear abs light coming on when the ignition is in the on position.
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:
9831
Component:
162000 structure:body
Summary:
Repairs to vinyl covered surfaces. *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:
9833
Component:
162000 structure:body
Summary:
Service tips for surface defect removal without repainting. *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:
9888
Component:
103000 power train:automatic transmission
Summary:
Information on a new transmission fluid usage chart. *yc
Bulletin:
9844
Component:
162000 structure:body
Summary:
Some difficulty in matching the texture of the oem anti-chip stone abrasion material to rpair materials when servicing. *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:
98514
Component:
105000 power train:driveline
Summary:
Concerns with a whistling or hissing noise from the main control area occuring while idling in drive and / or reverse on some vehicles. *tt
Bulletin:
9864
Component:
063000 engine and engine cooling:exhaust system
Summary:
Information on a buzzing or rattle noise from the exhaust system. *tt
Bulletin:
9868
Component:
185000 vehicle speed control:cruise control
Summary:
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
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:
98259
Component:
980000 unknown or other
Summary:
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
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:
982312
Component:
103000 power train:automatic transmission
Summary:
Issues regareding diagnostic trouble codes ( dtcs ) p0705, p0708, p1704, and / or p1705 may be stored in memory. *yc
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:
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:
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
Bulletin:
042107
Component:
103100 power train:automatic transmission:control module (tcm, pcm)
Summary:
General (pcm) power train control module programming procedures. *tt

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