1. Open front door (20124) and support using Rotunda Flexi-Work Table or equivalent.

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1 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 1 of 6 Section 01-03: Doors and Liftgate REMOVAL AND INSTALLATION 1997 Aerostar, Ranger Workshop Manual Doors Front Doors Removal and Installation 1. Open front door (20124) and support using Rotunda Flexi-Work Table or equivalent. 2. If installing a newfront door, remove all usable hardware, trim and glass parts from old door. Refer to Section 01-05A, Section 01-05B or Section Remove the upper and lower hinge access hole cover plate, if so equipped, and mark the location of the hinge on the door and body. 4. Remove bolts retaining front door to lower hinge. 5. Remove bolts attaching front door to front door upper hinge (22800).

2 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 2 of 6 6. If a hinge is to be replaced, remove the bolts attaching hinge to pillar. Remove hinge. 7. For installation, follow removal procedures in reverse order. 8. Adhere thefront door opening weatherstrip (20709) in proper position on thefront door. Use Weatherstrip Adhesive E8AZ A or equivalent meeting Ford specification ESB-M2G14-A. Include the belt seals. 9. Adjust front door. Refer to Adjustments in this section.

3 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 3 of 6 Item Part Number Description Front Door Front Door Upper Hinge 3 N S2 Retaining Bolts Front Door Opening Weatherstrip Lower Hinge A Tighten to Nm (18-26 Lb-Ft) Sliding Side Door Removal and Installation 1. Remove quarter trim panel (31012) or access hole cover plate. Refer to Section 01-05B.

4 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 4 of 6 2. Mark the position of upper guide bracket, lower guide bracket and the body side hinge bracket. 3. Remove the three bolts holding the body side hinge bracket. 4. Release the door latch, pull the body side hinge from the door and swing the door straight out to the side. 5. While supporting the door, remove the upper guide bracket bolts. 6. Remove the lower guide bolts, and remove the door. For installation, follow removal procedures in reverse order. Align upper and lower hinge brackets to disassembly marks. Tighten attaching bolts to Nm (16-25 lb-ft). Sliding Side Door Item Part Number Description 1 N S36 Nut Roller Assembly, Body Side Door, Upper Guide 3 N S40 Bolt Bracket Assembly, Body Side Door, Upper Guide Shim, Body Side Door, Upper Guide Hinge Assembly, Body Side Door 7 N S2 Screw and Washer Assembly 8 268A26 Guide Assembly, Body Side Door, Lower

5 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 5 of 6 9 N S101 Bolt 10 N99J291 Gasket Track Assembly, Body Side Door, Center Track 12 N S55 Screw Filler Assembly, Body Side Door, Center Track S100 Nut 15 N S55 Bolt 16 N S Washer Reinforcement (Extended Aerostar Only) A Tighten to 5-6 Nm (44-53 Lb-In) B Tighten to Nm (16-25 Lb-Ft) C Tighten to Nm (13-15 Lb-Ft) Dual Rear Doors, Aerostar Removal and Installation 1. Open and support the door with Rotunda Flexi-Work Table or equivalent. 2. Mark lower hinge to rear door (24630) location. 3. Remove three screw and washer assemblies retaining upper hinge torear door. 4. Remove two screw and washer assemblies retaining lower hinge torear door. 5. Slide rear door offsliding door hinge and roller (26800). Retain the back door hinge spacer(s) from sliding door hinge and roller to rear door. For installation, follow removal procedures in reverse order. If adjustments are needed, refer to Door Hinge adjustment procedure in this section. Hinges Dual Rear Door, Aerostar NOTE: The lower hinge need not be removed to remove upper hinge and vice versa. Upper Hinge Removal and Installation 1. Open and support the door with Rotunda Flexi-Work Table or equivalent. 2. Mark location of upper and lower hinges on door and body. 3. Remove plug button for hinge mounting driver access holes in pillar-inner rear corner and remove nut and washer assembly.

6 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13002.htm~gen~ref.htm Page 6 of 6 4. Remove five screw and washer assemblies retaining sliding door hinge and roller to door and body. 5. Slide upper hinge from vehicle. Retain door hinge spacer(s). For installation, follow removal procedures in reverse order. Lower Hinge Removal and Installation 1. Remove five screw and washer assemblies retaining lower hinge to sliding door hinge and roller and body. 2. Slide lower hinge from vehicle. For installation, follow removal procedures in reverse order.

7 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 1 of 10 Section 01-03: Doors and Liftgate ADJUSTMENTS 1997 Aerostar, Ranger Workshop Manual Dual Rear Door Alignment, Aerostar CAUTION: Do not cover up poor rear door (24630) alignment with a latch striker adjustment. 1. From inside of vehicle, remove plug button for hinge mounting driver access holes in pillar rear cover. 2. From inside the vehicle, loosen hinge screw and washer assembly just enough to permit movement

8 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 2 of 10 of the door with a padded pry bar. Retain sliding door hinge and roller (26800) to body for side-to-side or up-and-down adjustments. 3. Remove two screw and washer assemblies and loosen screw and washer assembly at the spacer slot location, retaining sliding door hinge and roller to rear door, to remove or insert backdoor hinge spacer(s) for fore and aft adjustments. 4. Loosen three screw and washer assemblies retaining lower hinge to body for up and down or fore and aft adjustment. 5. Loosen two screw and washer assemblies retaining lower hinge torear door for side to side adjustments. 6. Adjust rear door, as necessary. Tighten screw and washer assemblies, and nut and washer assembly. 7. Check the rear door fit to make sure there is no bind or interference with the adjacent panel. 8. Repeat operation until desired fit is obtained in terms of flushness and gap. 9. Check door latch striker plate (22008) alignment for proper rear door closing. Dual Rear Doors, Aerostar

9 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 3 of 10 Item Description Flushness Gap 1 Margin Between Window Modules Flush ± 2.5mm (0.08 In.) 2 Door Below Roof 1.5mm ± 2.5mm (0.05 In. ± 0.09 In.) 3 Door Inboard 1.5mm ± 2.5mm (0.05 In. ± 0.09 In.) 4 Character Line Alignment ± 2.0mm (0.07 In.) 5 Door Inboard Lower Flush ± 2.5mm (0.08 In.) 6 Margin Between Doors Flush ± 2.0mm (0.07 In.) 6mm ± 3.5mm (0.23 In. ± 0.13 In.) 5.0mm ± 2.5mm (0.19 In. ± 0.09 In.) 5.0mm ± 2.0mm (0.19 In. ± 0.08 In.) 5.0mm ± 2mm (0.19 In. ± 0.07 In.) 6.0mm ± 2.5mm (0.23 In. ± 0.08 In.) Note: Margins must be parallel within 1.5mm (0.06 in.).

10 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 4 of 10 Item Part Number Description

11 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 5 of 10 1 N S36 Screw and Washer Assembly Rear Door Hinge Spacer Rear Door Lower Door Hinge 5 N S36 Nut and Washer Upper Door Hinge A Tighten to Nm (16-25 Lb-Ft) Door Striker, Upper NOTE: Use an M-11 socket to loosen or tighten the nut and washer assemblies which attach the upper striker assemblies. The strikers can be adjusted laterally, and vertically, and shimmed fore and aft. Do not use more than four shims. To adjust striker, loosen attaching nuts so that striker can be moved around by hand. Close door firmly (thereby moving striker into proper position) and tighten retaining nuts. Door Striker, Lower NOTE: Use M-8 socket to loosen or tighten striker bolts. CAUTION: No more than four shims should be used to adjust clearance. The strikers can be adjusted fore and aft, and shimmed vertically. The latch striker should not be adjusted to correct door sag. The latch striker should be shimmed to achieve correct clearance between latch striker and latch. To check this clearance, close one door at a time and observe the alignment as the latch engages the striker. Move the striker assembly fore and aft to provide a flush fit at the door and the body. Dual Rear Back Door, Left Side

12 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 6 of 10 Item Part Number Description Shield Rear Door Latch Remote Control and Link 3 19A36 Door Latch Rod Retainer Assembly 4 31B43 Rear Door Upper Latch Release Cable Assembly 5 N S36 Screw Door Latch Knob Grommet 7 431C02 Door Latch Control Rod Assembly S Clip Rear Door Lower Latch Rod (Left Side) 10 4B147 Rear Door Latch Upper Striker (Left Side) Rear Door Upper Latch Assembly

13 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 7 of N S55 Screw 13 N S36M Nut and Washer Assembly 14 N S55 Bolt (to Fill Liftgate Striker Hole on Models with Dual Rear Doors) 15 N S55 Bolt Rear Back Door Lower Latch Assembly A53 Back Door Latch Lower Striker Spacer L06 Back Door Latch Lower Striker S54B Washer Rear Back Door Wedge and Plate Assembly Shield A Tighten to 7-11 Nm (62-97 Lb-In) Dual Rear Back Door, Right Side

14 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 8 of 10 Item Part Number Description Shield Roof Panel 3 433A52 Spacer Latch Upper Striker 5 431B42 Upper Latch Assembly 6 43B421 Upper Latch Release Cable 7 N S55 Screw 8 N S36M Nut and Washer Assembly 9 404B10 Door Lock Cylinder Retainer 10 Door Panel, Outer (Part of 24630)

15 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 9 of Door Latch Remote Control Rod Lock Set S2 Push Nut Inside Door Handle Door Latch Remote Control B44 Latch Control Rod S Clip S36 Nut and Washer Assembly Back Door Wedge and Plate Assembly 20 N S55 Screw Spacer L06 Latch Lower Striker Lower Latch Assembly (Right Side) 24 N S Rivet B48 Push-button Rod A38 Rear Door Electric Latch Actuator A34 Door Latch Knob Grommet B48 Pushbutton Upper Latch Release Cable Assembly Outside Handle Assembly A36 Door Lock Rod (2 Required) 32 N S2 Nut Rear Door Latch Remote Control and Link S Rod End Push Rod Clip S Pushpin A Tighten to 7-11 Nm (62-97 Lb-In) B Tighten to 2-3 Nm (18-27 Lb-In)

16 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13011.htm~gen~ref.htm Page 10 of 10

17 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13009.htm~gen~ref.htm Page 1 of 4 Section 01-03: Doors and Liftgate ADJUSTMENTS 1997 Aerostar, Ranger Workshop Manual Front Door Alignment CAUTION: Do not cover up a poor door alignment with a latch striker adjustment. 1. Determine which hinge bolts must be loosened to move the door in the desired direction. Mark hinge with pen or pencil for reference point. 2. Loosen the hinge bolts just enough to permit movement of the door with a padded pry bar. 3. Move the front door (20124) the distance estimated to obtain the desired fit. 4. Tighten bolts to specifications. 5. Check the door fit to make sure there is no bind or interference with the adjacent panel. 6. Repeat the operation until the desired fit is obtained. 7. Check the striker plate alignment for proper door closing. Refer to Section 01-14A for striker adjustment.

18 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13009.htm~gen~ref.htm Page 2 of 4 Item Part Number Description Upper Hinge 2 N S100 Screw Door Hinge and Check Front Door A Tighten to Nm (18-26 Lb-Ft) B Inboard/Outboard Adjustment C Forward/Rearward Adjustment

19 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13009.htm~gen~ref.htm Page 3 of 4 Item Part Number Description 1 N Nut and Washer Assembly 2 N Screw and Washer Assembly Front Door Upper Hinge Front Door Hinge and Check Assembly, Front Door, Lower A Tighten to Nm (18-26 Lb-Ft)

20 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13009.htm~gen~ref.htm Page 4 of 4

21 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 1 of 6 Section 01-03: Doors and Liftgate REMOVAL AND INSTALLATION 1997 Aerostar, Ranger Workshop Manual Guides and Wedges, Body Side Door, Aerostar Guide Bracket and Roller, Upper Removal and Installation 1. Open and support the door. 2. Mark the location of the upper bracket assembly to the door. 3. Remove the two bolts attaching the bracket assembly to the door. Remove roller assembly by backing it out of the track opening at the back. 4. If a new bracket assembly is being installed, transfer the roller assembly to the bracket assembly and set at the same location on brackets. 5. Position the roller assembly into the track. Set the new bracket assembly to the location marks. Install retaining bolts. 6. Adjust as described in this section.

22 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 2 of 6 Guide, Lower Removal and Installation 1. Open and support the door. 2. Mark the location of the lower guide bracket to the door. Remove three screws attaching guide. 3. Slide the guide forward in the track and tilt upward to remove from the front portion of the track. 4. Install new guide assembly into the front end of the lower track and slide guide to the door. Attach at the same location marks made in Step Adjust lower guide as described in this section.

23 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 3 of 6 Wedge Striker Plate, Aerostar CAUTION: For proper sliding door operation, it is critical that the door adjuster wedge (25342) and door latch striker, on the front face of the sliding door fit smoothly into the wedge pocket and door latch plate located in the B-pillar. If any of the following adjustments are made, realignment of the wedge and striker may be necessary. Removal and Installation 1. Open sliding door and mark location of each wedge and striker located on sliding door. 2. Remove the two attaching screws to remove striker wedge. Remove striker by turning. For installation, follow removal procedures in reverse order.

24 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 4 of 6 Item Part Number Description Body Side Door 2 N S36 Screw Wedge Striker Plate 4 200A31 Plug 5 431C04 Striker Wedge Pocket Plate, Aerostar CAUTION: For proper sliding door operation, it is critical that the wedge and striker on the front face of the sliding door fit smoothly in the wedge pocket and plate located in the B-pillar. If any of the following adjustments are made, realignment of the wedge and striker may be necessary. Removal and Installation 1. Open the sliding door. 2. Remove B-pillar trim panel or access hole cover plate. 3. Remove the two attaching screws and remove all hardware (plates, wedges, etc.) For installation, follow removal procedures in reverse order.

25 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 5 of 6 Item Part Number Description 1 N S2 Nut Plate 2 211A66 Reinforcement 3 N S39 Screw 4 264B54 Door Latch Plate Wedge Center Body Side Track, Aerostar Removal and Installation 1. Remove quarter trim panel (31012) or access hole cover plates. 2. Remove screw and nut attaching center track filler assembly at rear of center track. 3. Remove the five attaching nuts securing the center track assembly to the body. Remove track. For installation, follow removal procedures in reverse order.

26 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13005.htm~gen~ref.htm Page 6 of 6

27 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13012.htm~gen~ref.htm Page 1 of 2 Section 01-03: Doors and Liftgate ADJUSTMENTS 1997 Aerostar, Ranger Workshop Manual Liftgate Alignment, Aerostar The liftgate (40010) can be adjusted side to side and up and down by loosening the bolt and washer attaching the liftgate hinge (42900) to the body to roof trim panel (51968). Adding spacers permits in/out adjustment as required. The liftgate should be adjusted for an even and parallel fit with the door opening. Tighten nuts to Nm (13-20 lb-ft). Item Part Number Description Liftgate 2 N S Screw and Washer 3 N S Nut and Washer Roof Trim Panel

28 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13012.htm~gen~ref.htm Page 2 of Spacer Liftgate Hinge A Tighten to Nm (13-20 Lb-Ft) The liftgate/luggage compartment latch strikers (404A42) can be moved 4.0mm (5/32 inch) radially (side to side/back and forth) as necessary. After the adjustment, tighten fasteners to Nm (30-44 lb-ft).

29 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13007.htm~gen~ref.htm Page 1 of 3 Section 01-03: Doors and Liftgate REMOVAL AND INSTALLATION 1997 Aerostar, Ranger Workshop Manual Liftgate and Hinge, Aerostar Removal and Installation 1. Open liftgate (40010). 2. Remove upper rear header moulding. 3. Support liftgate in open position. 4. Disconnect liftgate lift support cylinders as described in this section. 5. Move roof trim panel (51968) out of position. Remove nut attaching hinge to roof trim panel. 6. Remove retaining screws and washers from liftgate hinge (42900) on each side of the liftgate. 7. Remove liftgate hinge. For installation, follow removal procedures in reverse order. Tighten fasteners to specifications. Aerostar

30 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13007.htm~gen~ref.htm Page 2 of 3 Item Part Number Description 1 N S55 Screw and Washer Assembly (2 Req'd Each Hinge) B Spacer, 4 Maximum Liftgate 4 N S36 Nut and Washer Assembly (2 Req'd Each Hinge) 5 427A98 Pad Assembly A Spacer, Liftgate Hinge on Body Liftgate Hinge A Tighten to Nm (13-20 Lb-Ft) B Tighten to Nm (16-25 Lb-Ft)

31 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13007.htm~gen~ref.htm Page 3 of 3

32 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13006.htm~gen~ref.htm Page 1 of 2 Section 01-03: Doors and Liftgate REMOVAL AND INSTALLATION 1997 Aerostar, Ranger Workshop Manual Liftgate Gas Cylinder Retainers, Aerostar Removal and Installation 1. Open and support liftgate (40010). 2. Remove liftgate lift support cylinders as described in this section. 3. Remove retainer assembly. For installation, follow removal procedures in reverse order. Tighten the retainers to Nm (15-21 lb-ft). Liftgate Gas Cylinder Retainers, Aerostar

33 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13006.htm~gen~ref.htm Page 2 of 2

34 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13014.htm~gen~ref.htm Page 1 of 2 Section 01-03: Doors and Liftgate LUBRICATION 1997 Aerostar, Ranger Workshop Manual Lubricant Weatherstrip, Door and Roof Side Rail Use Silicone Lubricant C0AZ AA (Jelly) or D7AZ AA (Spray) or equivalent meeting Ford specification ESR-M13P4-A on the door and window weatherstrips. It is recommended that silicone lubricant be applied to the weatherstrips whenever necessary. Silicone lubricant helps avoid weatherstrip squeaks, and retards excess weatherstrip wear caused by chafing between the door glass upper frame and the weatherstrip. It also helps to retain door window alignment by reducing friction between the glass frame and the rubber weatherstrip. Hinge, Door Use Multi-Purpose Grease Spray D7AZ AA or equivalent meeting Ford specification ESB-M1C93-A to lubricate door hinges. Hinge, Luggage Compartment Door Multi-Purpose Grease Spray D7AZ AA or equivalent meeting Ford specification ESB-M1C93-A is used to lubricate luggage compartment door hinges. Apply an even coat to all movable hinge surfaces when a binding condition occurs.

35 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13014.htm~gen~ref.htm Page 2 of 2

36 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 1 of 5 Section 01-03: Doors and Liftgate ADJUSTMENTS 1997 Aerostar, Ranger Workshop Manual Sliding Door Alignment, Aerostar CAUTION: For proper sliding door operation it is critical that the door adjuster wedge and striker on the front face of the sliding door fit smoothly into the wedge pocket and plate located in the B-pillar. If any of the following adjustments are made, re-alignment of the wedge and striker may be necessary. In or Out Adjustment NOTE: Support the sliding door to prevent up or down movement during adjustment. Front Upper 1. To adjust the front of the sliding door, loosen two nuts retaining the body side door bracket assembly to the upper guide roller assembly. 2. Move the roller assembly in or out as required to obtain a flush fit of the door to body.

37 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 2 of 5 Front Lower 1. Mark surface before loosening adjusting nut. Adjust lower front edge of the sliding door by loosening the adjusting nut on the lower guide assembly and move the door in or out as required to obtain a flush fit. The lower guide vertical roller is a load bearing roller and should roll easily within the lower track as the sliding door is opened or closed. 2. Vertical adjustment of lower guide is accomplished by loosening three bolts and moving base of guide. 3. If vertical adjustment is made to lower guide, inspect the upper guide to make sure the upper guide does not contact the bottom of the track housing or the upper guide roller contacts the top of the upper track.

$file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 3 of 5 Striker Rear Latch CAUTION: Striker adjusts in or out only.$

38 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 3 of 5 Striker Rear Latch CAUTION: Striker adjusts in or out only. Up and down adjustment is obtained with rear hinge and lower front guide. The sliding door latch is located at the rear of the door. When the door is closed the latch engages the striker which positions the rear of the door to the body. Adjusting the striker in or out will position the rear edge of the sliding door as required to obtain the proper fit to the body. Striker Rear Latch, Aerostar Hinge Assembly To adjust the sliding door fore or aft, loosen three bolts retaining the center door hinge to the door and adjust

39 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 4 of 5 hinge fore or aft as required to secure a proper door fit. Some up/down adjustment may be obtained from the center hinge by moving the center hinge strap up or down as desired prior to securing the retainer bolts. The vertical hinge rollers within the body center track assembly must be parallel to the top of the track and maintain a minimum clearance of 1mm (0.040 inch) from the top of the track from smooth operation. If hinge is adjusted vertically, evaluate striker setting for fit and centering. Sliding Side Door, Aerostar Item Part Number Description 1 N S36 Nut Roller Assembly, Body Side Door, Upper Guide 3 N S40 Bolt Bracket Assembly, Body Side Door, Upper Guide Shim, Body Side Door, Upper Guide Hinge Assembly, Body Side Door 7 N S2 Screw and Washer Assembly 8 268A26 Guide Assembly, Body Side Door Lower 9 N S101 Bolt 10 N99J291 Gasket Track Assembly, Body Side Door, Center 12 N S55 Screw

40 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13010.htm~gen~ref.htm Page 5 of Filler Assembly, Body Side Door, Center Track 14 N S55 Bolt 15 N S Washer S100 Nut Reinforcement (Extended Aerostar Only) A Tighten to 5-6 Nm (44-53 Lb-In) B Tighten to Nm (16-25 Lb-Ft) C Tighten to Nm (13-15 Lb-Ft)

41 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13018.htm~gen~ref.htm Page 1 of 1 Section 01-03: Doors and Liftgate SPECIAL SERVICE TOOLS/EQUIPMENT 1997 Aerostar, Ranger Workshop Manual SPECIAL SERVICE TOOLS/EQUIPMENT ROTUNDA EQUIPMENT Model Description Flexi-Work Table

42 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13017.htm~gen~ref.htm Page 1 of 2 Section 01-03: Doors and Liftgate SPECIFICATIONS 1997 Aerostar, Ranger Workshop Manual SPECIFICATIONS TORQUE SPECIFICATIONS Description Nut and Washer Assembly, Screw and Washer Assembly, Front Door Hinge to Body Nut, Sliding Door Guide Bracket, Upper Striker, Sliding Door Latch (Round Post) Sliding Door, Door Wedge Striker Screw, Wedge Screw, Door Latch Plate Screw and Washer Assembly, Nut and Washer Assembly, Front Door Hinge, Rear Door Hinge to Body/Door Nm Lb- Ft Screw and Washer Assembly, Liftgate Hinge to Liftgate Screw, Tailgate Hinge to Body Screw, Tailgate Striker, Cable Assembly, to Body Lb-In Screw, Tailgate Stop Assembly to Body Striker Assembly, Tailgate Screw, Tailgate Cable Assembly to Tailgate Screw, Composite Pickup Box, Inner Panel, Retainer Screw, Tailgate Roller Assembly to Body Retainer, Liftgate Lift Assembly Bolt and Washer Assembly, Liftgate Hinge Nut and Washer Assembly, Liftgate Hinge Screw and Washer Assembly, Liftgate Hinge Nut, Body Side Center Track Bolt, Sliding Door Bracket Screw and Washer Assembly, Sliding Door to Hinge Bolt, Sliding Door Guide Assembly, Lower, Reinforcement

43 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13017.htm~gen~ref.htm Page 2 of 2 Bolt, Liftgate Striker Assembly Screw and Washer Assembly, Nut and Washer Assembly, Back Door Hinge, Upper and Lower to Body/Door Fasteners, Back Door Latch, Upper and Lower Striker, Wedge Plate, Assemblies Nut and Washer Assembly, Inside Back Door Handle

44 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 1 of 6 Section 01-03: Doors and Liftgate REMOVAL AND INSTALLATION 1997 Aerostar, Ranger Workshop Manual Weatherstrips, Aerostar Removal 1. Cut or separatefront door opening weatherstrip (20709) andrear door body weatherstrip (253A10) around opening at seam. 2. Loosen and pry away from body flange with a flat tool such as a putty knife or equivalent. 3. Pull front door opening weatherstrip and rear door body weatherstrip outward and away from flange working upward, along the top, and around the opening. Installation 1. NOTE: Do not stretch weatherstrip during installation. Clean any residual adhesive or material from flange or body surface by scraping carefully with a flat tool such as a putty knife or wipe with a cloth using Extra Strength Tar and Road Oil Remover B7A AA or equivalent meeting Ford specification ESR-M5B106-A. 2. Start installation at the proper area indicated in the illustration. Compress the front door opening weatherstrip and rear door body weatherstrip onto the flange and continue working across or around the opening. 3. Insert sponge plug into loose end of front door opening weatherstrip and rear door body weatherstrip. 4. Cut front door opening weatherstrip andrear door body weatherstrip, if necessary, 6-12mm longer than required and butt ends together. Avoid overlapping. 5. To install roof side rail weatherstrip (51222), apply Weatherstrip Adhesive E8AZ A or equivalent meeting Ford specification ESB-M2G14-A to forward pushpin only if required. 6. Insert pushpin near front at paint mark, then work outward and rearward installing weatherstrip carrier onto flange. 7. Peel protective backing off adhesive tape at rear molded seal or where required. 8. Aerostar body lock pillar cover installation should be started at top, then down lock pillar with adhesive tape protective backing removed, ending above the rocker panel. 9. Installation of back door opening weatherstrip assembly is same as body door openings. Clean surfaces with alcohol before applying adhesives. Remove protective backing from adhesive tape where required and apply pressure to installed assembly at these areas. Weatherstrips, Body Door Openings and Roof Side Rail, Aerostar

45 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 2 of 6 Item Part Number Description Roof Side Rail Weatherstrip Front Door Opening Weatherstrip 3 253A10 Rear Door Body Weatherstrip A Starting Point, Roof Rail Installation B Starting Point, Front Door Opening Weatherstrip Installation C Starting Points, Side Door Opening Weatherstrip Installation Weatherstrips, Body Door Openings and Roof Side Rail, Ranger

46 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 3 of 6 Item Part Number Description Roof Side Rail Weatherstrip

47 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 4 of Front Door Front Door Lower Weatherstrip Front Door Opening Weatherstrip 5 Front Door Upper Weatherstrip A Starting Point, Body Door Opening Weatherstrip Installation Weatherstrips, Dual Rear Doors

48 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 5 of 6 Item Part Number Description Panel, Roof B Weatherstrip Assembly, Back Door

49 file://c:\tso\tsocache\vdtom_3244\svk~us~en~file=svk13004.htm~gen~ref.htm Page 6 of 6 3 M3G58-A Adhesive Tape Weatherstrip Assembly, Back Door Opening A Weatherstrip Assembly, Back Door Rear Door Scuff Plate

DOORS - REAR TABLE OF CONTENTS

23-88 DOORS - REAR XJ DOORS - REAR TABLE OF CONTENTS page AIR EXHAUSTER...88....88 DOOR...89....89 DOOR GLASS...89....89 EXTERIOR HANDLE...89....89 HINGE...90....90 INSIDE HANDLE ACTUATOR...90....90 page