This DIY repair and service manual by Haynes, covers all 1986 -1997 Ford Aerostar 2WD mini-van models.
Book Excerpt: 1986-1997 Ford Aerostar Repair Manual 4.0L V6 ENGINE

OIL PAN AND BAFFLE | REMOVAL AND INSTALLATION REMOVAL
(Refer to illustrations 14.4 and 14.5.) NOTE: The factory recommends removal of the transmission when removing the oil pan to assure proper pan sealing upon re-installation. However, if proper care is exercised during resealing, removal of the transmission is not necessary.

1. Disconnect the battery negative cable.
2. Remove the starter motor (refer to Chapter 5).
3. Remove the transmission-to-oil pan bolts and spacers at the two mounting pad locations.
4. Remove the oil pan-to-block fasteners along with the two Torx-type fasteners at rear of the crankcase on each side of the oil seal (see illustration). Remove the pan from the engine.
5. If necessary, remove the baffle fasteners and remove the baffle (see illustration).
6. Using a gasket scraper, thoroughly clean all old gasket material from the pan and its mounting surfaces. Remove residue and oil film with solvent such as acetone or lacquer thinner.
INSTALLATION
(Refer to illustrations 14.12a, 14.12b and 14.13) CAUTION: Since two of the oil pan bolts are attached to the transmission, spacers are used between the oil pan and transmission to allow for standard manufacturing and installation tolerances. The spacer gap must be measured and the correct spacer selected and installed or oil pan damage and/or oil leaks may occur.
7. Place the oil pan on the engine and install several fasteners finger tight. Measure the gap between the oil pan and the transmission at the spacer mounting pad locations.
8. If the engine is out of the vehicle, place a straightedge across the transmission mounting surface on the block and one of the mounting pad locations and measure the gap.
9. Record the gap measurement.
10. Move to the second mounting pad location and record the measurement. Remove the oil pan.
11. Verify that the original spacers are of the correct thickness or select new spacers to compensate for the gap. Spacers are available in three thicknesses from your dealer (see this Chapter's Specifications).

CLUTCH AND DRIVETRAIN

STARTER/CLUTCH INTERLOCK SWITCH | REMOVAL AND INSTALLATION

1. Detach the wire harness connector from the interlock switch.
2. Remove the interlock switch-to-bracket screw and pry the end of the rod off of the clutch pedal pin.
3. Position the adjuster clip approximately 1-inch form the end of the rod.
4. Install the end of the rod onto the clutch pedal pin.
5. With the clutch pedal all the way up, swing the switch down into place. Install the mounting screw and tighten it securely.
6. Push the clutch pedal to the floor which automatically adjusts the switch.
7. Confirm that the engine starts only when the clutch pedal is depressed to the floor. If it doesn't, remove the adjusting clip from the rod and position it closer to the switch. Push the pedal to the floor and check the switch operation again. If the engine still doesn't crank over, or cranks over when the pedal is in the released position, replace the switch with a new one.

Subject: , 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Ford Aerostar service, maintenance, repair. ISBN-10: 1563923742 | ISBN-13: 9781563923746 | Haynes 36004