This is Ford factory service documentation for the Aerostar, supplied as a set of 114 section documents totalling 6,542 pages. It is the same documentation structure Ford dealer technicians worked from, organised by system rather than by task, and it runs from VIN identification through to the wiring and circuit protection diagrams.

Which vehicles this manual fits

• Fits: Ford Aerostar
• Covers years: 1997, 1996, 1995, 1994, 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986
• Engine options: 3.0L V-6 and 4.0L V-6, each with its own engine, fuel charging and electronic ignition sections
• Gearbox: 4R44E and 5R55E automatic transmissions, M5OD 5-speed manual, plus mechanical-shift, electronic-shift and E-4WD transfer cases
• Language: English
• Pages: 6,542 across 114 section files
• File type: ZIP archive containing PDF documents

Inside this manual

Every entry below is a section that exists in the document set:

Sample pages from this manual

These are real pages taken from the document set:

What you can repair with it

The engine sections are split by displacement, so overhaul, timing, cooling and emission control work is documented separately for the 3.0L and the 4.0L. Driveline coverage runs from the clutch and M5OD manual gearbox through both automatic transmissions to the transfer cases and both ring gear sizes, including the Traction-Lok limited slip differential.

Electrical work is supported by the wiring and circuit protection section, the module communications network and the Generic Electronic Module, alongside the charging, starting and instrument cluster sections. Braking is covered for front disc, rear drum and both anti-lock arrangements, and the supplemental air bag section documents the passive restraint system.

Manual language and format

This manual is written in English. It downloads as a single ZIP archive containing PDF documents organised into the sections listed above, so you can open just the section you need rather than searching one very large file. The PDFs can be read on Windows and Mac computers, tablets and phones, and printed page by page.

Questions about this manual

How is coverage organised?
By system rather than by year. The engine sections are split between the 3.0L and 4.0L V-6, and the driveline sections cover the 4R44E and 5R55E automatics, the M5OD manual gearbox and the E-4WD transfer cases. Please check the section list above against your van's specification before buying.

Does it cover the 4.0L V-6?
Yes. There are separate sections for Engine 4.0L V-6, Fuel Charging and Controls 4.0L, and Ignition Electronic 4.0L, in addition to the equivalent 3.0L sections.

Are wiring diagrams included?
Yes. Wiring and Circuit Protection is included, together with Module Communications Network and the Generic Electronic Module section.

Does it cover four-wheel drive models?
Yes. Transfer Case E-4WD, Electronic Shift and Mechanical Shift are all covered, along with the E-4WD front drive axle and front suspension and wheel hubs.

Which automatic transmissions are documented?
The 4R44E and the 5R55E, each with its own section, plus separate coverage of automatic transmission cooling and external controls.

How you receive it

Payment is processed securely and the download link is issued immediately afterwards, so there is nothing to wait for and nothing shipped. The file is yours to keep and re-download within the link period.