Ford Aerostar 1986-1997 Repair Guide



See Figures 1, 2 and 3

Inspect inlet pipes, outlet pipes and mufflers for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. 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 the clamps, brackets and insulators for cracks and stripped or badly corroded bolt threads. When flat joints are loosened and/or disconnected to replace a shield pipe or muffler, replace the bolts and flange nuts if there is reasonable doubt that their service life is limited.

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Fig. Fig. 1: Typical exhaust system for the Aerostar vehicles

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Fig. Fig. 2: Exhaust components for the 2.8L and 3.0L engine equipped vehicles

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Fig. Fig. 3: Exhaust system and major components for vehicles equipped with the 4.0L engine

The exhaust system, including brush shields, must be free of leaks, binding, grounding and excessive vibrations. These conditions are usually caused by loose or broken flange bolts, shields, brackets or pipes. If any of these conditions exist, check the exhaust system components and alignment. Align or replace as necessary. Brush shields are positioned on the underside of the catalytic converter and should be free from bends which would bring any part of the shield in contact with the catalytic converter or muffler. The shield should also be clear of any combustible material such as dried grass or leaves.