Technical Information
ATTACHMENT IIIOWNER NOTIFICATION PROGRAM 88S55 1986/1987 AEROSTAR SLIDING DOOR MECHANISM
TECHNICAL INSTRUCTIONS
Use existing service procedures found in Shop Manual - Section 72-22 and in TSB 86-6-17 (attached).
FIGURE A:
A. FOR ALL 1986 and 1987 AEROSTARS
1. Replace center hinge assembly and center track assembly. See Fig. A.
B. ADDITIONAL SERVICE REQUIRED FOR 1986 AEROSTARS
1. Replace center track filler assembly if required to mate to new center track assembly. See Shop Manual, Section 72-22.
FIGURE B:
2. Inspect and if necessary, replace upper roller assembly if roller has the plastic-tire design. See Fig. B.
3. Install upper track stop bumper and install bumper insert into upper track stop bumper. Reference TSB 86-6-17. See Fig. B.
FIGURE C:
4. Inspect and correct, if necessary, lower track opening dimensions (27.5mm to 26.0mm). Reference TSB 86-6-17. See Fig. C.
LIGHT TRUCK 1986 AEROSTAR Complaints concerning Aerostar sliding door malfunctions can be corrected by replacement with new track components in conjunction with adjustments outlined in the following procedure.
Figure 16:
Disengagement of the Lower Guide Assembly (268A26) Figure 16
1. Potential and/or disengagement of the lower track guide can be corrected by using a rubber mallet to reduce the entire lower track opening sufficiently to entrap the horizontal roller guide assembly. Correct track opening dimension is 27.5mm to 26mm (1-3/32" to 1-1/32"). (See Figure 16.) After performing this procedure, move the door forward and rearward to assure proper function.
FIGURE 17:
Disengagement of the Upper Guide Roller Assembly (25028) Figure 17, View A
1. Open the door and examine the roller for damage. If damage is evident, the upper roller assembly guide (25028) must be replaced with a new steel guide assembly, part number E69Z-1125028-B.
2. Examine the rubber stop at the rear of the upper track. If the existing stop is the same as shown in Figure 17, View B, insert part number E69Z-1125- 084-A into the center of the rubber stop as shown.
NOTE: Three types of upper track rubber stops have been used in production, therefore, if the stop is solid rubber or a hose type rubber stop, it is not necessary to install the above insert plug (1125084).
3. Cycle door and adjust, if necessary, to assure that the upper roller guide assembly (25028) rides freely within the track and the upper edge of the sliding door fits flush to the body.
FIGURE 18:
Hinge Assembly Bodyside Door (26800) Figure 18
1. Open the sliding door to full open position and inspect center hinge roller. If damaged or broken, the hinge assembly with steel rollers, part number E69Z-1126800-C installed.
Refer to Aerostar Shop Manual, Section 72-22 on installation of center hinge assembly.
CAUTION: During adjustment, it is critical to assure that the (2) wedges on the front face of the sliding door fit smoothly into the (2) wedge Pockets located in the "B" pillar.
PART PART NAME CLASS
E69Z-1125028-B Roller Assembly BG
E69Z-1126800-C Hinge Assembly BG
E69Z-1125084-A Rubber Bumper BG
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbusable within the provisions of the Warranty and Policy Manual.
OPERATION: SP26826A86- Disengagement of lower guide.
TIME 0.3 Hrs.
OPERATION: SP26826B86- Disengagement of lower guide and disengagement of upper guide roller assembly.
TIME 0.4 Hr.
OPERATION: SP26826C86- Disengagement of lower guide, disengagement of upper guide roller assembly, replacement of bodyside hinge.
TIME 0.9 Hr.
DLR. CODING: Basic Part No. 7025028 - Code 01