Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1994AEROSTAR AWD V6-245 4.0LREPAIR AND DIAGNOSISINSTRUMENT PANEL, GAUGES AND WARNING INDICATORSDASHBOARD / INSTRUMENT PANELSERVICE AND REPAIRINSTRUMENT PANEL - REPLACEMENT
1994 Ford Aerostar AWD V6-245 4.0L
Instrument Panel - Replacement
1994 Ford Aerostar AWD V6-245 4.0LSECTION Instrument Panel - Replacement
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
1. Disconnect battery positive cable.
2. Disconnect wiring connector on instrument panel located in the engine compartment, by loosening bolt and separating connectors.
3. Remove left and right windshield inside mouldings.
4. Remove defroster grille.
5. Remove glove compartment door finish panel.
6. Remove instrument panel steering column cover.
7. Remove four screws attaching the steering column lower reinforcement. Remove reinforcement.
8. Remove right and left cowl side panels.
9. Remove two nuts and hood latch control handle and cable assembly from left cowl side and reinstall the nuts to hold the bracket and relay.
10. Disconnect the wiring on the left cowl side panel and, if equipped, the vacuum hose harness connector. Number and location of connectors may vary depending on optional equipment.
11. Disconnect the brake light switch wiring connector. Disconnect the Clutch Pedal Position Switch (CPP switch) on manual transmission vehicles.
12. Remove steering column-to-extension shaft pinch bolt. Compress extension shaft toward engine and separate from the column U-joint.
13. Disconnect the transmission control selector indicator from steering column.
14. Disconnect wiring to windshield wiper intermittent control module and, if equipped, the wiring to low oil relay. Both are located to the right of steering column.
15. Disconnect radio antenna lead in cable at the right cowl side panel.
16. Disconnect heater temperature cable. If equipped, disconnect vacuum hose harness connector.
17. Remove the five screws attaching the top of the instrument panel to the cowl side panel top.
18. Remove the one nut attaching the lower right side of the instrument panel to the cowl side panel.
19. Remove the two rearward nuts and loosen the two forward nuts located to the right of the steering column attaching the instrument panel to the center mounting bracket.
NOTE: The following steps (20, 21, 22) require two technicians.
20. Support the instrument panel. Remove three bolts and one nut attaching the instrument panel to left cowl side panel.
21. Carefully pull the instrument panel rearward and disconnect any remaining wires or other components.
22. Carefully remove instrument panel through the left front door.
23. If replacing the instrument panel, transfer all the components to the replacement instrument panel.
For installation, follow removal procedures in reverse order.
1. Disconnect battery positive cable.
2. Disconnect wiring connector on instrument panel located in the engine compartment, by loosening bolt and separating connectors.
3. Remove left and right windshield inside mouldings.
4. Remove defroster grille.
5. Remove glove compartment door finish panel.
6. Remove instrument panel steering column cover.
7. Remove four screws attaching the steering column lower reinforcement. Remove reinforcement.
8. Remove right and left cowl side panels.
9. Remove two nuts and hood latch control handle and cable assembly from left cowl side and reinstall the nuts to hold the bracket and relay.
10. Disconnect the wiring on the left cowl side panel and, if equipped, the vacuum hose harness connector. Number and location of connectors may vary depending on optional equipment.
11. Disconnect the brake light switch wiring connector. Disconnect the Clutch Pedal Position Switch (CPP switch) on manual transmission vehicles.
12. Remove steering column-to-extension shaft pinch bolt. Compress extension shaft toward engine and separate from the column U-joint.
13. Disconnect the transmission control selector indicator from steering column.
14. Disconnect wiring to windshield wiper intermittent control module and, if equipped, the wiring to low oil relay. Both are located to the right of steering column.
15. Disconnect radio antenna lead in cable at the right cowl side panel.
16. Disconnect heater temperature cable. If equipped, disconnect vacuum hose harness connector.
17. Remove the five screws attaching the top of the instrument panel to the cowl side panel top.
18. Remove the one nut attaching the lower right side of the instrument panel to the cowl side panel.
19. Remove the two rearward nuts and loosen the two forward nuts located to the right of the steering column attaching the instrument panel to the center mounting bracket.
NOTE: The following steps (20, 21, 22) require two technicians.
20. Support the instrument panel. Remove three bolts and one nut attaching the instrument panel to left cowl side panel.
21. Carefully pull the instrument panel rearward and disconnect any remaining wires or other components.
22. Carefully remove instrument panel through the left front door.
23. If replacing the instrument panel, transfer all the components to the replacement instrument panel.
For installation, follow removal procedures in reverse order.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.