This Chilton repair and service manual covers 1986-1997 Ford Aerostar Vans, U.S. and Canadian models.
Book Excerpt: 1986-1997 Ford Aerostar Repair Manual
ENGINE AND ENGINE OVERHAUL
RADIATOR | REMOVAL AND INSTALLATION (See Figures 56 thru 62)
With the engine cold, drain the cooling system by removing the radiator cap, attaching a 3/8 in. (9.5mm) inside diameter hose to the draincock nipple, then opening the draincock at the lower rear corner of the radiator tank. Drain the coolant out of the radiator, through the hose, and into a suitably sized container.
CAUTION: When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
Remove the rubber overflow tube from the radiator and store it out of the way.
Remove the cooling fan and clutch assembly from the water pump pulley. For more details, refer to the cooling fan procedures later in this section.
Remove the radiator fan shroud upper attaching screws, then lift the shroud out of the lower retaining clips. Lift it and the cooling fan/clutch out of the engine compartment.
Loosen the upper and lower hose clamps at the radiator and remove the hoses from the radiator connections.
If equipped with an automatic transmission, disconnect the transmission cooling lines from the radiator fittings. Disconnect the transmission cooler tube support bracket from the bottom flange of the radiator by removing the screw.
Remove the two radiato9r upper attaching screws.
Tilt the radiator back (rearward) about 1 in. (25mm) and lift it directly upward, clear of the radiator support and the cooling fan.
If either hose is being replaced, loosen the clamp at the engine end and slip the hose off the connection with a twisting motion.
Lift the fan shroud off of the fan, then remove it from the vehicle.
Remove the radiator lower support rubber insulators.
Install the coolant hose(s) to the engine connections, making sure any bends are oriented exactly as the old hose for alignment purposes.
If the radiator is being replaced, transfer the lower support rubber insulators to the new part. The radiator cooling fins should be cleaned of any dirt or debris and any bent fins should be CAREFULLY straightened.
Install the radiator into the engine compartment, making sure the lower rubber insulators are properly positioned in the radiator support. Be careful to clear the fan with the radiator to avoid damage to the cooling fins.
Connect the upper attaching bolts to the radiator support and tighten them to 12-20 ft. lbs. (17-27 Nm).
The balance of the installation is the reverse of the removal.
Fill and bleed the cooling system.
SUSPENSION AND STEERING
FRONT STABILIZER BAR | REMOVAL AND INSTALLATION (See Figures 19 and 20)
Raise the van and support it safely on jackstands.
Loosen and remove the nuts retaining the stabilizer bar to the lower control arm link on each side.
Remove the insulators and disconnect the stabilizer bar from the links.
If required, remove the nuts retaining the links to the lower control arm, then remove the insulators and links.
Remove the bolts retaining the bar mounting bracket to the frame and remove the stabilizer bar. If required, remove the insulators from the stabilizer bar.
If the stabilizer bar insulators are being replaced, install them on the stabilizer bar. Place the bar, insulators and mounting bracket in position on the frame and install the retaining bolts. Tighten the retaining bolts to 16-24 ft. lbs. (22-33 Nm).
If removed, connect the link and insulators to the lower control arm. Install and tighten the nuts to 12-18 ft. lbs. (16-24 Nm).
Connect the links and insulators to the stabilizer bar, then install and tighten the nuts to 12-18 ft. lbs. (16-24 Nm).
Once all mounting nuts are tightened, lower the vehicle.
UPPER CONTROL ARM | REMOVAL AND INSTALLATION
(See Figure 21)
Place the steering wheel and front tires in the centered (straight ahead) position. NOTE: Anytime the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.
Raise the van and support it safely with jackstands placed under the frame lifting pads. A hydraulic floor jack should be placed under the control arm to raise and lower the arm during coil spring removal. Make sure the van is supported securely on the jackstands and only work on one side at a time.
NEVER service both the front suspension assemblies at the same time.
Remove the spindle, as described in this section.
Remove the bolt retaining the cowl drain bracket and bolt retainer plate, then remove the bracket and plate.
Matchmark the position of the control arm mounting brackets on the flat plate. (continued).