Ford Aerostar 1997 Service Guide

General Information

Table of Contents

Maintenance Schedule and Record ........... 3

General Maintenance Information ............ 3

What Maintenance Schedule Do You

Follow? ............................................................. 6

Normal Schedule ........................................... 7

Severe Duty Schedule ................................ 24

Owner Maintenance Checks ..................... 49

Maintenance Schedule and Record

The required Scheduled Maintenance Services listed in this booklet are considered essential to the proper operation, safety and performance of your Ford Motor Company vehicle. We recommend that you also perform the Owner Maintenance Checks listed. These services are matters of day-to-day care that are also important to the proper operation of your vehicle. The recommended lubricants, fluids and service parts conforming to Ford Specifications are available from your dealer.

This booklet gives you a place to record the services that are performed on your vehicle so that you can keep a record of when parts should be checked or replaced. Give your Maintenance Schedule booklet to the dealer service manager.

Maintenance: An investment

An investment which will pay dividends in the form of improved reliability, durability, and resale value.

To assure the durability of your vehicle and its emission control systems, it is necessary that scheduled maintenance be performed at the designated intervals.

Ford strongly recommends the use of genuine Ford replacement parts. If other than Ford or Motorcraft parts or Ford authorized remanufactured parts are used for maintenance replacements or for the service of components affecting emission control, such non-Ford parts should be equivalent to genuine Ford Motor Company parts in performance and durability. It is the owner’s responsibility to determine the equivalency of such parts. Please consult your warranty booklet for complete warranty information.

No Cost PCV Valve Replacement

THE PCV VALVE IS A CRITICAL EMISSION COMPONENT. YOUR DEALER WILL REPLACE THE VALVE AT NO COST AT 60,000 MILES/96,000 KILOMETERS (EXCEPT CANADA AND CALIFORNIA VEHICLES).

Wheel Lug Nuts

Wheel lug nuts must be retightened to proper torque specifications at 500 miles/800 km of new vehicle operation. Proper torque specifications are provided in your Owner Guide. Also retighten to proper torque specification at 500 miles/800 km after (1) any wheel change or (2) any other time the wheel lug nuts have been loosened.

PRE-DELIVERY CHECK

Pre-Delivery Service Inspection Completed

❑

What Maintenance Schedule Do You Follow?

Normal

Schedule

Follow the Normal Schedule for most normal everyday driving conditions.

Severe Duty

Schedule

Follow the Severe Duty Schedule if your driving habits FREQUENTLY include one or more of the following conditions:

Towing a trailer or carrying a heavy load.

❑

Operating in severe dust conditions.

❑

Extensive idling, such as police, taxi or

❑

door-to-door delivery service. Snowplowing

❑

Short trips of less than 10 miles (16 km)

❑

when outside temperatures remain below 0˚F (-18˚C).

Normal Schedule

NOTE: Items for Emission Control Service are shown in this type and style.

For items marked with number in parentheses such as (1), see footnote at end of this section.

Regular

Maintenance

Intervals

for the Normal

Schedule

5,000 MILES (8,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

Normal Schedule 7

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

10,000 MILES (16,000 Kilometers)

Change engine oil and replace oil filter.

❑

15,000 MILES (24,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

8 Normal Schedule

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

20,000 MILES (32,000 Kilometers)

Change engine oil and replace oil filter.

❑

25,000 MILES (40,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

Normal Schedule 9

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

30,000 MILES (48,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Replace air cleaner filter. (2)

❑

Replace fuel filter (Recommended but not required

❑

for California vehicles).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect and lubricate front wheel bearings

❑

(4x2 vehicles only). Inspect parking brake system for damage and

❑

operation. Change transfer case oil. (4X4)

❑

Lubricate throttle kickdown or TV lever ball

❑

studs.

10 Normal Schedule

Inspect and lubricate front suspension ball

❑

joints, bushings, arms, springs and rear jounce bumpers for wear or damage.

35,000 MILES (56,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Normal Schedule 11

40,000 MILES (64,000 Kilometers)

Change engine oil and replace oil filter.

❑

45,000 MILES (72,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

12 Normal Schedule

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

50,000 MILES (80,000 Kilometers)

Change engine oil and replace oil filter.

❑

Change engine coolant initially at 50,000 miles

❑

(80,000 km) or 48 months. Thereafter, change engine coolant every 30,000 miles (48,000 km) or 36 months (Gasoline engines only).

55,000 MILES (88,000 Kilometers)

Change engine oil and replace oil filter.

❑

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

Normal Schedule 13

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

60,000 MILES (96,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Inspect accessory drive belt(s).

❑

Replace air cleaner filter. (2)

❑

Replace PCV valve. (3)

❑

Replace fuel filter (Recommended but not required

❑

for California vehicles).

Inspect disc brake system, lubricate caliper

❑

slide rails. Inspect drum brake systems, hoses and lines.

❑

Inspect and lubricate front wheel bearings

❑

(4x2 vehicles only). Inspect parking brake system for damage and

❑

operation. Lubricate throttle kickdown or TV lever ball

❑

studs.

14 Normal Schedule

Inspect and lubricate front suspension ball

❑

joints, bushings, arms, springs and rear jounce bumpers for wear or damage.

Replace all front axle and transfer case lube

❑

quantities every 60,000 miles (96,000 km) or if the axle has been submerged in water (E-4WD vehicles only).

Change transfer case oil. (4X4)

❑

65,000 MILES (104,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Rotate tires and adjust air pressure. (1)

❑

Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Normal Schedule 15

70,000 MILES (112,000 Kilometers)

Change engine oil and replace oil filter.

❑

75,000 MILES (120,000 Kilometers)

Change engine oil and replace oil filter.

❑

Inspect engine cooling system, hoses, and clamps;

❑

and check coolant strength every 15,000 miles (24,000 km) or 12 months.

Rotate tires and adjust air pressure. (1)

❑

Inspect and lubricate automatic transmission

❑

shift linkage. Lubricate steering linkage suspension,

❑

driveshaft U-joint if equipped with grease fittings and lubricate slip yoke (if equipped).

Inspect exhaust system for leaks, damage or

❑

loose parts. Remove any foreign material trapped by exhaust system shielding.

NOTE: It is normal for a certain amount of

moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.

Inspect disc brake system, lubricate caliper

❑

slide rails.

16 Normal Schedule

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