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Guest · Posted: Thu Aug 16, 2007 1:32 am Post subject: Aerostar airbag code 45

I'm posting this simply to correct some erroneous information in an
earlier post. I have a '92 or '93 Aerostar that had, when I got it, a
constantly blinking airbag light. It was blinking out a code 45.

Earlier posters correctly indicated that this means that a crash
sensor is not functioning properly. They have misidentified the
location of the affected sensor. The sensor that this code refers to
is mounted not behind the kick panel, but on the front radiator
support. Being outside, of course, means it is exposed to the
elements. What happens is that it develops corrosion (rust) between
it and the component it is mounted to, which severs its ground
connection, causing the fault that triggers the light. It is easy to
reach: it is accessible through the grille.

The solution is equally simple: unbolt it, sand off the rust on the
sensor (a small black box retained by only one bolt, if I recall
correctly) and off its mount, apply some dielectric grease (to inhibit
further corrosion in the future), and reassemble. Voila! The light's
now off when you turn on the ignition, and airbag functionality has
been restored.

Apparently the previous owner of my van found the same posts I did:
scrape damage to the headliner and windshield indicates that he had
removed the inside panel to access the crash sensor located by the
driver's foot. What a pain!

It may be years overdue, but I know there are others out there with
1992 / 1993 (and other years) Ford Aerostars with flashing airbag
lights. Put away your black electrical tape and break out the 1/4
inch drive ratchets!