The Ford Aerostar spans 1984–1997 with 68 recorded NHTSA recalls and a 3.5/5 ForCar reliability score. The years to approach with caution are 1993, 1992, 1994 (most owner complaints); the cleanest are 1984, 1985, 1997. It delivers competitive fuel economy and NHTSA-rated safety.
How we score: NHTSA crash-test safety (40%), recall frequency across all years (25%) and the share of owner complaints involving a crash, fire or injury (35%). Based on NHTSA & EPA data — not user reviews.
Overview
The Ford Aerostar is one of the most popular vehicles in its class, produced from 1984 to 1997 across multiple generations.
How to read a Ford Aerostar VIN — every digit explained
Every Ford Aerostar carries a unique 17-character VIN stamped at the factory. Each position is a code — together they spell out where, when and how your car was built. Here's exactly what every digit means.
- WMI (1–3) — country & manufacturer. Tells you it's a Ford and the country it was built in (real Ford codes below).
- VDS (4–8) — model, body style, engine, trim & restraints. The 8th digit is the engine code.
- Check digit (9) — a math check that proves the VIN is genuine.
- Model year (10) — the year it was built (e.g. R = 2024, S = 2025).
- Plant (11) — which factory assembled this Aerostar.
- Serial (12–17) — the unique sequential production number.
- USA1F1 · 1F7 · 1FA · 1FB · 1FM · 1FT
- Canada2FA · 2FM · 2FT · 2LM · 2LN · 2ME
- Mexico3FA · 3FB · 3FM · 3FT · 3LN · 3MA
- GermanyWF0 · WF1
- Norway1FL
Digits 4–17 — the engine code (8th), model-year letter (10th) and plant — follow the universal SAE standard, identical on every car. For the full year-code table (2001–2026), country codes and where the VIN is stamped on your Aerostar, see the complete guide to reading a VIN.
How many recalls does the Ford Aerostar have?
The Ford Aerostar has 68 recorded NHTSA recalls across 1984–1997. Pick a year below to see its recalls — then verify open recalls against your specific VIN.
1997 Ford Aerostar recalls 5
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Vehicle Speed Control:cables
What's wrong. Vehicle description: minivans equipped with 3.0l engines. An accelerator cable was kinked during installation, causing the core wires to eventually fray.
Risk. This could increase the friction in the cable, causing the throttle to be slow to return to idle. This condition could result in a stuck throttle.
Fix. Dealers will install a new accelerator cable.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1996 Ford Aerostar recalls 6
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Equipment:other:labels
What's wrong. The certification labels on the involved vehicles has incorrect rear tire inflation pressure designations. This does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."
Risk. Incorrect inflation pressures could cause premature wear of the rear tires. .
Fix. Owners will be provided with correct certification labels and instructions for installing these labels. Dealers can install this label if the owner so desires.
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Latches/locks/linkages:doors:latch
What's wrong. When in the secondary latched position, the driver door latches may open when subjected to transverse loads less than that specified in fmvss no. 206, "door locks and door retention components."
Risk. The driver's door, when closed only to the secondary latched position, may not sustain a 1,000 pound transverse load.
Fix. Dealers will inspect and, if necessary, replace the driver door latch.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1995 Ford Aerostar recalls 7
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Equipment:mechanical:carrier/rack
What's wrong. The spare tire supplied with the vehicle can contact the brake lines on the rear axle if it is mounted in the underbody spare tire carrier. Such contact could result in fracture of a rear brake line.
Risk. This can result in reduced vehicle brake capability.
Fix. Dealers will install a lower profile mini-spare tire on the existing mini-spare wheel. The new tire will allow the mini-spare to be installed with appropriate clearances in the underbody spare tire carrier.
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical System:wiring:front Underhood
What's wrong. Vehicle description: mini vans. Heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. The vehicle could experience a loss of power and become immobilized and the fuel gauge may be erratic.
Risk. Heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. The short circuit could also have the potential for a vehicle fire.
Fix. Dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Equipment:other:labels
What's wrong. The certification label on these vehicles have incorrect rear tire sizes listed. P215/70r14sl should be p215/75r14sl. This does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."
Risk. Consequence of non-compliance: the incorrectly sized rear tire would not have sufficient load capacity for the vehicle's specified gross axle weight rating, increasing the potential for premature tire failure.
Fix. Owners will be mailed a supplementary label containing the correct rear tire information and instructions for installing the label on their vehicles. If owners prefer, their dealer can install the label for them.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1994 Ford Aerostar recalls 5
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical System:wiring:front Underhood
What's wrong. Vehicle description: mini vans. Heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. The vehicle could experience a loss of power and become immobilized and the fuel gauge may be erratic.
Risk. Heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. The short circuit could also have the potential for a vehicle fire.
Fix. Dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1993 Ford Aerostar recalls 4
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1992 Ford Aerostar recalls 5
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical System:ignition:switch
What's wrong. Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk. This can cause over heating and the potential for a vehicle fire.
Fix. Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Power Train:transfer Case (4-wheel Drive)
What's wrong. Vehicle description: all wheel drive passenger minivans. (this includes all 1992 awd aerostars not previously included in safety recall 97v-204/97s83). These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
Risk. This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Fix. Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Service Brakes, Hydraulic
What's wrong. Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
Risk. Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Fix. Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
1991 Ford Aerostar recalls 4
Power Train:automatic Transmission
What's wrong. When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Risk. Driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. All of these conditions canresult in a vehicle accident.
Fix. Repair the transmission with a new park pawl.
Electrical System:ignition
What's wrong. The ignition switch could experience an internal short circuit.
Risk. This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Fix. Dealers will replace the ignition switch.
Seat Belts:front:anchorage
What's wrong. Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
Risk. Vehicles would not comply with fmvss 210.
Fix. Replace noncomplying sofa bar with bar that meets requirements.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
1990 Ford Aerostar recalls 7
Power Train:automatic Transmission
What's wrong. When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Risk. Driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. All of these conditions canresult in a vehicle accident.
Fix. Repair the transmission with a new park pawl.
Electrical System:ignition
What's wrong. The ignition switch could experience an internal short circuit.
Risk. This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Fix. Dealers will replace the ignition switch.
Service Brakes, Hydraulic:foundation Components:master Cylinder
What's wrong. Inability to maintain pressure in the secondary system of the master cylinder (controls braking of rear wheels) could increase brake pedal travel and reduce brake performance at temperatures less than 40 degrees.
Risk. This would cause reduced braking effectiveness andincreased stopping distance that could result in a crash or collision.
Fix. Install new design master cylinder incorporating a redesigned seal.
Seat Belts:front:anchorage
What's wrong. Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
Risk. Vehicles would not comply with fmvss 210.
Fix. Replace noncomplying sofa bar with bar that meets requirements.
Fuel System, Gasoline:storage:tank Assembly
What's wrong. Vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. Territories covered by the federal statutes. The upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. Fuel vapor or leakage could occur at these cracks.
Risk. If an ignition source is present, a fire could result.
Fix. Dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. This coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Seats:front Assembly:recliner
What's wrong. The second row right hand seat assembly has a tilt forward function. A latch retains the seat in the normal ride postion, and this latch may release under severe frontal impact conditions, allowing the seat to pivot forward.
Risk. In the event of vehicle accident, the seat could pivotforward, increasing the risk of injury to the occupant.
Fix. Replace seat pawl assembly with a revised design assembly.
1989 Ford Aerostar recalls 6
Power Train:automatic Transmission
What's wrong. When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Risk. Driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. All of these conditions canresult in a vehicle accident.
Fix. Repair the transmission with a new park pawl.
Electrical System:ignition
What's wrong. The ignition switch could experience an internal short circuit.
Risk. This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Fix. Dealers will replace the ignition switch.
Seat Belts:front:anchorage
What's wrong. Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
Risk. Vehicles would not comply with fmvss 210.
Fix. Replace noncomplying sofa bar with bar that meets requirements.
Fuel System, Gasoline:storage:tank Assembly
What's wrong. Vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. Territories covered by the federal statutes. The upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. Fuel vapor or leakage could occur at these cracks.
Risk. If an ignition source is present, a fire could result.
Fix. Dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. This coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Seats:front Assembly:recliner
What's wrong. The second row right hand seat assembly has a tilt forward function. A latch retains the seat in the normal ride postion, and this latch may release under severe frontal impact conditions, allowing the seat to pivot forward.
Risk. In the event of vehicle accident, the seat could pivotforward, increasing the risk of injury to the occupant.
Fix. Replace seat pawl assembly with a revised design assembly.
1988 Ford Aerostar recalls 5
Electrical System:wiring
What's wrong. Vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.
Risk. Should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. The possibility exists for a fire if thewires are exposed to combustible materials.
Fix. Installation of a relay with wires of gauge adequate to protect the circuit.
Structure:body:hatchback/liftgate:support Device/strut
What's wrong. Some liftgate gas cylinder-to-body attachment ball studs may fracture in either the open or closed position.
Risk. If a ball stud fractures, the liftgate will not remain inthe open position. Bodily injury could result if the liftgate drops whilesomeone is under it.
Fix. Replace the gas cylinder-to-body attachment ball studs.
Electrical System:ignition
What's wrong. The ignition switch could experience an internal short circuit.
Risk. This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Fix. Dealers will replace the ignition switch.
Fuel System, Gasoline:storage:tank Assembly
What's wrong. Vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. Territories covered by the federal statutes. The upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. Fuel vapor or leakage could occur at these cracks.
Risk. If an ignition source is present, a fire could result.
Fix. Dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. This coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
1987 Ford Aerostar recalls 5
Electrical System:wiring
What's wrong. Vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.
Risk. Should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. The possibility exists for a fire if thewires are exposed to combustible materials.
Fix. Installation of a relay with wires of gauge adequate to protect the circuit.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
What's wrong. Spring lock fuel line coupling may not be properly engaged.
Risk. Coupling could disengage due to fuel pressure,vibration, and engine movements; this would cause loss of fuel which, inpresence of an ignition source, creates a fire risk.
Fix. Install retainer clips over the couplings to prevent coupling separation and fuel leakage.
Structure:body:hatchback/liftgate:support Device/strut
What's wrong. Some liftgate gas cylinder-to-body attachment ball studs may fracture in either the open or closed position.
Risk. If a ball stud fractures, the liftgate will not remain inthe open position. Bodily injury could result if the liftgate drops whilesomeone is under it.
Fix. Replace the gas cylinder-to-body attachment ball studs.
Seat Belts:front:anchorage
What's wrong. Vans were produced without plastic cover designed to cover outboard seat back pivot hinge allowing webbing of front passenger-side safety belts to become abraded or cut due to contact with exposed hinge.
Risk. Damage to belt webbing could weaken belts to point offailure increasing risk of injury in an accident or a sudden stop.
Fix. Install plastic pivot cover; replace belts as necessary.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
1986 Ford Aerostar recalls 9
Suspension:rear:springs:leaf Spring Assembly
What's wrong. There may be inadequate welding in some underbody structural areas, including those at the rear suspension attachments, which may cause it to separate. Consequence of defect: if rear suspension attachments should separate from the underbody during vehicle use, the axle could shift during acceleration or braking and may adversely affect the steering control which may lead to an accident.
Fix. Reinforce suspect weld locations and modify to prevent weld failure.
Electrical System:wiring
What's wrong. Vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.
Risk. Should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. The possibility exists for a fire if thewires are exposed to combustible materials.
Fix. Installation of a relay with wires of gauge adequate to protect the circuit.
Fuel System, Gasoline:storage:tank Assembly
What's wrong. Fuel tanks may have been scored or penetrated when floor pan mounting holes for the partitions were drilled. Consequence of defect: fuel leakage may occur and in the presence of an ignition source, the potential for a fire would exist.
Fix. Replace fuel tanks as necessary.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
What's wrong. Spring lock fuel line coupling may not be properly engaged.
Risk. Coupling could disengage due to fuel pressure,vibration, and engine movements; this would cause loss of fuel which, inpresence of an ignition source, creates a fire risk.
Fix. Install retainer clips over the couplings to prevent coupling separation and fuel leakage.
Seats
What's wrong. Wiring for the power lumbar seat system was routed directly beneath the seat cushion springs and may be abraded by the springs.
Risk. This could result in a short circuit which may createsufficient heat to start a fire in the seat cushion pad and/or trim cover.
Fix. Install a fuse within the power lumbar electrical circuit.
Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap
What's wrong. Insufficient interference fit between fuel tank filler pipe and grommet could result in an inadequate seal which could allow fuel to seep from the joint.
Risk. In the presence of an ignition source, fuel leakage could result in a fire.
Fix. Install a revised design grommet.
Seat Belts:front:anchorage
What's wrong. Vans were produced without plastic cover designed to cover outboard seat back pivot hinge allowing webbing of front passenger-side safety belts to become abraded or cut due to contact with exposed hinge.
Risk. Damage to belt webbing could weaken belts to point offailure increasing risk of injury in an accident or a sudden stop.
Fix. Install plastic pivot cover; replace belts as necessary.
Service Brakes, Air:disc:rotor
What's wrong. Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk. Loss of braking can result.
Fix. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
Fuel System, Gasoline:delivery:fuel Pump
What's wrong. Certain federal-mogul aftermarket fuel pumps sold under the brand names of carter, accuflow, napa, truflow, parts depo, and parts master, shipped between august 2006 and july 2007 for use on the vehicles listed above. The fuel pump diaphragm in certain production runs may have been improperly installed or inadequately tested which may cause the fuel pump to leak.
Risk. A leaking fuel pump could create a vehicle fire hazard.
Fix. Federal-mogul will notify owners and replace the defective fuel pumps free of charge. The recall began on october 15, 2007. Owners can contact federal-mogul at 248-354-7700.
Best and worst years for the Ford Aerostar
Based on NHTSA owner-complaint volume across 14 tracked years, the worst years are 1993, 1992, 1994 and the best (fewest complaints) are 1984, 1985, 1997.
ForCar aggregate — our own analysis of complaint volume, not published by NHTSA.
| Year | Owner complaints | Top issue | Verdict |
|---|---|---|---|
| 1984 Aerostar | — | Best | |
| 1985 Aerostar | — | Best | |
| 1986 Aerostar | Electrical System | Average | |
| 1987 Aerostar | Electrical System | Average | |
| 1988 Aerostar | Fuel System | Average | |
| 1989 Aerostar | Electrical System | Average | |
| 1990 Aerostar | Electrical System | Average | |
| 1991 Aerostar | Electrical System | Average | |
| 1992 Aerostar | Power Train | Avoid | |
| 1993 Aerostar | Electrical System | Avoid | |
| 1994 Aerostar | Electrical System | Avoid | |
| 1995 Aerostar | Electrical System | Average | |
| 1996 Aerostar | Wheels | Average | |
| 1997 Aerostar | Electrical System | Best |
What are the most common Ford Aerostar problems?
The most-reported Ford Aerostar problems are Air (6 reports), Other (7 reports) and Seats (38 reports) — out of 2,701 owner complaints NHTSA holds for the model. Here's how they break down:
Most-reported components — tap a category to read what owners actually experienced:
Electrical System 654 Read
Ignition switch short circuit caused wiring to overheat and burn in steering column area.
While driving vehicle moved in full force on its own. Wiring harness under the hood wrapped itself around the accelerator. This defect did not allow consumer to control vehicle which did result in an automobile accident. *ak
Tl*the contact owns a 1995 ford aerostar. While driving 20 mph, the vehicle shut off without warning. The contact opened the hood and noticed that the fuel lines were extremely hot before they burst into flames. The contact sustained a burned right hand. The fire department stated that the fuel pump caused the fire. A police report was filed. The manufacturer stated that his vin was not included in nhtsa campaign id number 99v028000 (electrical system: wiring: front under hood). The current and failure mileages were 150,000.
The vehicle caught fire prior to recall notice 99v-029 due to defective electrical system, the consumer sustained burns to his forearm while trying to obtain items from the vehicle. Nlm
Vehicle experienced recall component failure (99v-029) ignition switch , prior to recall notification resulting in vehicle fire, injury and burns to consumer. *mjs
The alternator failed short circuit. Massive amounts of current passed from the battery through the alternator, which burst into flames. The fault caused the engine to stall due to lack of ignition and it was extremely difficult to steer and stop the vehicle as a result of loss of power steering and power brakes. Smoke was pouring from the front of the vehicle. When i managed to stop and open the hood, the alternator, which was glowing red inside, burst into flames and set fire to cables and rubber hoses around it. I received burns to my hands trying to put the fire out. Lucky for me another motorist stopped and he had an extinguisher. I have now had two fires of this type, one on each of my vehicles. Yesterday i went to an alternator remanufacturing company here in monterrey, and the manger told me that he has had five engine bay fires in aerostar minivans in recent months. In the 'good old days' understand there was a fusible link between the alternator charging line and the battery + terminal. There should be a fuse in this circuit because it is connected directly to the battery!! Not only is the fire a very serious problem, but there is a serious risk in the event of this fault, that the overload on the battery will cause it to burst, showering everything and everyone around it with hot sulfuric acid. Please note although the vehicle was purchased in the usa i am currently living in monterrey, mexico. My phone is 01152-8-349-7152 and email is [email protected]. *ak
Vehicle caught on fire 6 hours after being parked. State fire marshall determined that ignition switch caused fire. Home and vehicle were totaly lost. 3 children had to jump through window to escape the fire, one sliced tendons on wrist. Ignition switch was replaced under recall 96v071000 on 30 sep 1997. Information provided by sherrie hansen, attorney.*ak
My 1997 ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. The ford dealer did the recall work but did not fix or examine the steering column or the components that burned or over heated as a result of the overload. [xxx] updated 07/19/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)
I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major ford dealer (brandon ford), and they are refusing to help me. I called ford customer service and he said my vin is not listed for a recall, but yet had no answer for me when i asked why is my vehicle not on the recall list, when it is in the group of vehicles that were recalled and that are catching on fire while driving down the road. Over 887,000 were recalled for fire related problems, but they refuse to even look at mine. So, can i keep driving it? I don't know if it was a one time thing, or what.....
The vehicle was parked in front of the residence and it caught on fire. Driver called the fire department to extinguish the fire. No injuries. Vehicle was towed and totaled by the insurance company. *ak
Power Train 407 Read
During a crash bumper/hood/fender/switch/grill/core support/air conditioner condensor/fan belt/transmission and driver's door were damanged from impact to the driver's side. Also seat came off track and mechanic repaired it, as well as the air bag did not deploy. *ak
My clients, the frederick family (father, mother and 3-yr-old daughter) sustained third degree burns when their 1994 ford aerostar van spontaneously caught fire while travelling on i-40 near needles, california. Fire was the result of the transfer case output shaft bushing displacement, thereby failing the drive shaft which struck the pavement, then richocheted into the fuel tank and pierced the tank, allowing raw fuel to escape and ignite, probably from the catalytic converter or sparks from the drive shaft striking the pavement. This case is in litigation in united states district court in las vegas, nevada, being case no. Cv-s-00-0444-ktd-rlh. Peter chase neumann, attorney for plaintiffs, 136 ridge street, reno, nv 89501. 775-786-3750.
Upon starting the vehicle, it accelerated at a high speed and crashed into a building. The driver's foot was on the brake pedal when sudden acceleration occurred. The vehicle was totaled. The insurance company indicated that the incident was inconclusive. There was a transmission recall 91v189000, but this vehicle was not included in the recall due to vin. *ak *sc *jb
Transmission jumped out of park gear twice, causing vehicle to roll backwards/accident/injuries.
Vehicle rolled backwards twice while in park gear, once causing injuries. *aw
November 21, 1998 this complaint has already been investigated and a recall has been ordered. We had already repaired our 1994 ford aerostar van because it broke down on october 4, 1997. We submitted a request for reimbursement on august 7, 1998. As of november 21, 1998, we have not received a reimbursement check. Is there a window of time for the manufacturer to mail reimbursement checks? I feel that ford motor company should reimburse me for expenses incurred as a result of the defect plus interest and late fees for failing to send a reimbursement check within a reasonable time (3 weeks). I feel that $3,292.60 would be a fair reimbursement at this time. Ford motor co. Has been collecting interest on the money it owes its customers or investing it. Safety recall number: 97s83 campaign # 97v204000 i submitted receipts to: stanley carroll radford ford, inc. 6832 lee highway radford, va 24141 (540) 639-3934 i have contacted the ford customer assistance center 1-800-392-3673 several times as well as mr. Carroll. They promise to check into the progress of my reimbursement and call back. They do not call back. Thank you in advance for your time and careful consideration of my message. Sincerely, carolyn c. Mccain (540) 731-1945 (h) (540) 674-4663 (w) [email protected]
Was driving 7 kids in vehicle, going about 45mph, when transfer case was leaking under normal driving conditions. Another truck forced aerostar off road due to being on fire. Flames had made tank glow red. Flames put out w/fire extinguisher. Vehicle towed to ford dealer. Repairs done on transfer case under recall 97v-204.000. Took vehicle home & parked it. Started to leak. This was the 8th transfer case replaced in vehicle & the 2nd to catch on fire.manufacturer agreed to buy vehicle back from owner at price it was paid for. *ak
Told by mechanic that power train snapped and car drove out of control. Was unable to put the car in park or neutral. The car only stopped when mechanic turned the ignition key off.
5 year old child disengaged transmission from park. Keys were not in vehicle. Vehicle was off and in park. Vehichle rolled down driveway across stree and hit parked car. *ak
The brake shift interlock feature failed, causing accident/injuries.
Service Brakes 303 Read
Frontal collision impact 12:00 position 25 mph, brake failure abs lockup on wet surface airbag on drivers side partically deployed, also lap/shoulder belt fail.
The consumer has been experiencing problems with airbags and brakes. The consumer was involved in a front collision in whichbrakes failed to operate. When applied brakes, pedal went to the floorboard. In addition, the airbags failed to deploy. The manufacturer has been contacted.*ak
While driving the brakes failed resulting in vehicle collision with three injuries, upon expection of the brake pedal travel and reservoir (oshp units 977), no pressure on the pedal and no fluid in the reservoir (ohio traffic crash report) *mjs
In an accident at 40-45mph, 12:00 position, driver's side airbag did not deploy. Abs braking system had rear wheel lockup with 100 feet of skid marks. *ak
Scared to buy another ford aerostar
Traveling 45mph down the mountain when vehicle in front failed to signal. Had applied the brakes & vehicle started to hydroplane & rearended the other vehicle. Upon impact, driver's air bag did not deploy. The vehicle was considered totaled. *ak *ml
Owner was going at approximately 45 mph. Owner applied the brakes and the brakes went to the floor. Owner says that the front right brake hose line popped right off. Causing the vehicle to lose all brake pressure preventing the vehicle from stopping. Provide further details. *nm
Auto-tran:heard loud noise coming from underneath car;shifted from park to drive;engine accelerated; hit house;kept going/ foot on brake;shut off ignition. Tt
Abs brakes; when applying brakes in a sudden stop the rear brakes locked up, causing rear of vehicle to pull from right to left, causing an accident, in which vehicle rolled over. Please provide details. *ak consumer stated that the anti-lock brake light would illuminate, consumer also stated when brakes are applied the rear end of vehicle would fishtail. Consumer took vehicle in for service, but dealer could not duplicate problem. On another occasion, consumer applied brakes to avoid hitting a merging vehicle, the vehicle fished tailed, and turned parrarell to the curb and proceeded to flip onto its left side. Consumer received injuries to back and knees. *tt
Went to apply the brakes and there was no brakes, to avoid hitting vehicle, consumer hit a pole , has abs anti-lock brakes and having other problems . Please describe . *ak
Hydraulic 296 Read
Frontal collision impact 12:00 position 25 mph, brake failure abs lockup on wet surface airbag on drivers side partically deployed, also lap/shoulder belt fail.
The consumer has been experiencing problems with airbags and brakes. The consumer was involved in a front collision in whichbrakes failed to operate. When applied brakes, pedal went to the floorboard. In addition, the airbags failed to deploy. The manufacturer has been contacted.*ak
While driving the brakes failed resulting in vehicle collision with three injuries, upon expection of the brake pedal travel and reservoir (oshp units 977), no pressure on the pedal and no fluid in the reservoir (ohio traffic crash report) *mjs
In an accident at 40-45mph, 12:00 position, driver's side airbag did not deploy. Abs braking system had rear wheel lockup with 100 feet of skid marks. *ak
Scared to buy another ford aerostar
Traveling 45mph down the mountain when vehicle in front failed to signal. Had applied the brakes & vehicle started to hydroplane & rearended the other vehicle. Upon impact, driver's air bag did not deploy. The vehicle was considered totaled. *ak *ml
Owner was going at approximately 45 mph. Owner applied the brakes and the brakes went to the floor. Owner says that the front right brake hose line popped right off. Causing the vehicle to lose all brake pressure preventing the vehicle from stopping. Provide further details. *nm
Auto-tran:heard loud noise coming from underneath car;shifted from park to drive;engine accelerated; hit house;kept going/ foot on brake;shut off ignition. Tt
Abs brakes; when applying brakes in a sudden stop the rear brakes locked up, causing rear of vehicle to pull from right to left, causing an accident, in which vehicle rolled over. Please provide details. *ak consumer stated that the anti-lock brake light would illuminate, consumer also stated when brakes are applied the rear end of vehicle would fishtail. Consumer took vehicle in for service, but dealer could not duplicate problem. On another occasion, consumer applied brakes to avoid hitting a merging vehicle, the vehicle fished tailed, and turned parrarell to the curb and proceeded to flip onto its left side. Consumer received injuries to back and knees. *tt
Went to apply the brakes and there was no brakes, to avoid hitting vehicle, consumer hit a pole , has abs anti-lock brakes and having other problems . Please describe . *ak
Engine And Engine Cooling 223 Read
During a crash bumper/hood/fender/switch/grill/core support/air conditioner condensor/fan belt/transmission and driver's door were damanged from impact to the driver's side. Also seat came off track and mechanic repaired it, as well as the air bag did not deploy. *ak
My clients, the frederick family (father, mother and 3-yr-old daughter) sustained third degree burns when their 1994 ford aerostar van spontaneously caught fire while travelling on i-40 near needles, california. Fire was the result of the transfer case output shaft bushing displacement, thereby failing the drive shaft which struck the pavement, then richocheted into the fuel tank and pierced the tank, allowing raw fuel to escape and ignite, probably from the catalytic converter or sparks from the drive shaft striking the pavement. This case is in litigation in united states district court in las vegas, nevada, being case no. Cv-s-00-0444-ktd-rlh. Peter chase neumann, attorney for plaintiffs, 136 ridge street, reno, nv 89501. 775-786-3750.
The vehicle was parked in the office parking lot. Suddenly a customer notified the consumer that there was a vehicle fire. The fire department extinguished the fire. The manufacture will make contact with the consumer for inspection. *nm *nm
Dt: the contact stated 1994, ford van caught on fire on the freeway on 8-8-05. She was not having problems prior to the fire. The fire seemed to be electrical and originated under the hood. *ak *jb updated 2/7/2006 - the consumer received recall 97v204000 on nov 13, 1997 for the transfer case/driveshaft but the dealer refused to make the repairs. This failure of this component could result in a fire. The consumer received information from nhtsa on two recalls for the vehicle. One was 99v028000 for the electrical wiring under the hood and the other one was 99v029000 for the ignition switch. *nm
Ea98016; while driving the vehicle stalled and a fire came from underneath the vehicle. Cause unknown. Currently at dealer. Please provide details. *ak
Vehicle caught on fire, cause unknown, could have been an electrical system wiring short. *ak *yh
Van caught on fire in the engine and dash area and burned up. Van was parked and engine off when fire happened.
While making a turn vehicle stalled and died, resulting in a vehicle fire. Vehicle was totaled. The manufacturer and dealer will be notified. *ak
Engine fire.
Driver's power window malfunctioned. In addition, transmission failed/abs light intermittently comes on/master cylinder failed, causing an accident/air conditioning compressor failed/tie rods replaced/tail lights repeated ly replaced/ignition switch failed, causing a fire/repeated engine oil leaks and catalytic converter replaced.
Fuel System 211 Read
Automatic fuel cutoff failed when vehicl was struck by other vehicle and rolled over, landing on its roof.
The engine did not turn off when vehicle was in an accident car turned over. Tt
My clients, the frederick family (father, mother and 3-yr-old daughter) sustained third degree burns when their 1994 ford aerostar van spontaneously caught fire while travelling on i-40 near needles, california. Fire was the result of the transfer case output shaft bushing displacement, thereby failing the drive shaft which struck the pavement, then richocheted into the fuel tank and pierced the tank, allowing raw fuel to escape and ignite, probably from the catalytic converter or sparks from the drive shaft striking the pavement. This case is in litigation in united states district court in las vegas, nevada, being case no. Cv-s-00-0444-ktd-rlh. Peter chase neumann, attorney for plaintiffs, 136 ridge street, reno, nv 89501. 775-786-3750.
If vehicle is equipped with "fuel cut off valve" it did not operate at time of crash. The vehicle's engine kept running. Airbag inflation may not have been sufficient. Driver received 2nd degree burn on forearm from airbag. Burn size of dollar bill. *ak
Tips of injector travels through fuel lines developes high pressure developing cracks. Resulting in vehicle fire. Tt
The inertia switch for fuel system was triggered. *ak
My 1997 ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. The ford dealer did the recall work but did not fix or examine the steering column or the components that burned or over heated as a result of the overload. [xxx] updated 07/19/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)
Fuel line had crack, causing fuel to leak, resulting in a fire. No warning was given. *ak
Fuel system failed, causing vehicle fire
Vehicle was sold without safety inspection being performed. Unburnt fuel fumes are going into passenger compartment causing dizziness, nasea, and disorientation & headaches. Mechanic tells me car is moving bomb as electrical components could cause a fire or explosion within passenger compartment. Possible fuel injector failure or fuel injector gasket failure. I am scared to death to operate vehicle!*ak
Gasoline 204 Read
Automatic fuel cutoff failed when vehicl was struck by other vehicle and rolled over, landing on its roof.
The engine did not turn off when vehicle was in an accident car turned over. Tt
My clients, the frederick family (father, mother and 3-yr-old daughter) sustained third degree burns when their 1994 ford aerostar van spontaneously caught fire while travelling on i-40 near needles, california. Fire was the result of the transfer case output shaft bushing displacement, thereby failing the drive shaft which struck the pavement, then richocheted into the fuel tank and pierced the tank, allowing raw fuel to escape and ignite, probably from the catalytic converter or sparks from the drive shaft striking the pavement. This case is in litigation in united states district court in las vegas, nevada, being case no. Cv-s-00-0444-ktd-rlh. Peter chase neumann, attorney for plaintiffs, 136 ridge street, reno, nv 89501. 775-786-3750.
If vehicle is equipped with "fuel cut off valve" it did not operate at time of crash. The vehicle's engine kept running. Airbag inflation may not have been sufficient. Driver received 2nd degree burn on forearm from airbag. Burn size of dollar bill. *ak
Tips of injector travels through fuel lines developes high pressure developing cracks. Resulting in vehicle fire. Tt
The inertia switch for fuel system was triggered. *ak
My 1997 ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. The ford dealer did the recall work but did not fix or examine the steering column or the components that burned or over heated as a result of the overload. [xxx] updated 07/19/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)
Fuel line had crack, causing fuel to leak, resulting in a fire. No warning was given. *ak
Vehicle was sold without safety inspection being performed. Unburnt fuel fumes are going into passenger compartment causing dizziness, nasea, and disorientation & headaches. Mechanic tells me car is moving bomb as electrical components could cause a fire or explosion within passenger compartment. Possible fuel injector failure or fuel injector gasket failure. I am scared to death to operate vehicle!*ak
Fuel pump failed/shorted out, resulting in a fire. *ak
Air Bags 136 Read
During a crash bumper/hood/fender/switch/grill/core support/air conditioner condensor/fan belt/transmission and driver's door were damanged from impact to the driver's side. Also seat came off track and mechanic repaired it, as well as the air bag did not deploy. *ak
Frontal collision impact 12:00 position 25 mph, brake failure abs lockup on wet surface airbag on drivers side partically deployed, also lap/shoulder belt fail.
Our van was the first vehicle hit in a four car pile up. Our van and two other vehicles were stopped for a red light when struck. Our van sustained substancial enough damage both in front and behind to total it. The drivers air bag never deployed so i'm having to receive some physical therapy for neck injuries. I wonder if my air bag had deployed would i have had to go through these doctors appointments and therapy. Do i have any recourse? Dt
While driving 40mph another vehicle hit consumer's vehicle on the front corner driver's side. It bent the frame, and airbags didn't deploy. *ak
Consumer involved in an accident and air bags did not deploy. Passenger had seat belt on on hit her head on windshield, causing a slight concussion and other injuries. Driver and third passenger sustained bumps/bruises. *ak
The vehicle in a frontal collision at 40mph and the airbag did not deploy. Tt
In a multiple car pile-up, with speeds between 35 and 50 mph the driver's airbag in our van (vehicle number #3 of 4 involved) did not deploy. Our vehicle was damaged across the entire front and the entire back bumpers (grill, hatch...). My daughter was examined by a physician and missed some work. If the airbag had deployed she should have received some protection.*ak
The vehicle went over a puddle of water and lost control.. Driver's side seat belt unfastened at that point. Vehicle then rolled over four times. Upon impact, air bags did not deploy. Driver was ejected through the windshield, and sustained a broken collar bone and three broken ribs. Also passenger in the front seat sustained internal head and back injuries. *ak
The consumer has been experiencing problems with airbags and brakes. The consumer was involved in a front collision in whichbrakes failed to operate. When applied brakes, pedal went to the floorboard. In addition, the airbags failed to deploy. The manufacturer has been contacted.*ak
Vehicle was slowing down going 35-45mph in the right slow lane. When brakes were applied, vehicle picked up more speed, causing consumer to lose control. Vehicle ran into one of the beams under underpass of the highway. Upon impact, front driver's air bag didn't deploy. Consumer's face hit steering. Consumer had 16 stiches in bottom lip. Consumer had a case, and was not allowed to contact dealer at this time.*ak
Source: NHTSA owner complaints, all model years. Bar = share of total complaints. Full reports searchable on NHTSA.gov.
Ford Aerostar specifications & dimensions
The 1997 Ford Aerostar. Full dimensions below — engine, horsepower and trim decode from your VIN. For the original factory build — MSRP, trim and standard equipment — rebuild the Ford Aerostar window sticker.
| Specs cache warming… |
Source: NHTSA vPIC / Transport Canada vehicle specifications. Metric values converted to imperial; generation ranges approximate.
Ford Aerostar cargo space, seating & interior room
How much the Aerostar holds — passengers and cargo. Seating, cargo and interior dimensions vary by trim and seat configuration — decode your VIN for the exact build.
Exact seating capacity, third-row availability, legroom and headroom decode from your VIN or vary by trim — the original factory equipment & options list shows what each trim included.
Passenger & cargo volume from EPA fueleconomy.gov (largest configuration). Seats, legroom and headroom from NHTSA vPIC on VIN decode.
Ford Aerostar tire size, oil type & owner specs
The fitment owners look up most — tires, wheels, oil and batteries. Exact wheel and tire sizes decode from your VIN or the driver's door-jamb placard; the universal items are listed below.
Exact tire, wheel, oil grade, capacity and battery group are added per trim and model year — decode your VIN above for the factory fitment. Universal items shown as-is.
What MPG does the Ford Aerostar get?
MPG cache warming… reload in a moment.
What engines does the Ford Aerostar have? Power & range
Powertrain data warming… reload in a moment.
How much does a Ford Aerostar cost to own?
A Ford Aerostar holds its value well. A typical example keeps roughly 56% of its value after five years — losing about 44% to depreciation. Check what a used Aerostar is worth today or browse current used-market prices before you buy or sell. Fuel, maintenance and insurance add to the total cost to own.
| Age | Value retained | Est. resale value | Lost to depreciation |
|---|---|---|---|
| Year 1 | 84% | $25,200 | −$4,800 |
| Year 2 | 76% | $22,800 | −$7,200 |
| Year 3 | 68% | $20,400 | −$9,600 |
| Year 4 | 61% | $18,300 | −$11,700 |
| Year 5 | 56% | $16,800 | −$13,200 |
What goes into the five-year cost to own:
- Depreciation — the biggest cost: this Aerostar loses about 44% of its value over five years. See the full depreciation curve by age.
- Fuel — based on EPA economy at roughly 15,000 miles a year.
- Maintenance & repairs — routine service, tires and wear items as the Aerostar ages.
- Insurance — varies by driver, state and trim; get a quote for your exact figure.
Resale & depreciation are ForCar estimates from typical segment value-retention curves — not a live market quote. Fuel from EPA fueleconomy.gov at ~15k mi/yr.
Is the Ford Aerostar safe?
NHTSA crash-test ratings aren't published for the Aerostar yet — see the top-rated safest cars instead.
Tired of ads? Go Pro.
- Zero ads — clean, fast pages
- Exact mileage-adjusted car values
- Full research reports + PDF
- Market charts & price-drop alerts
- …and much more
How many miles does a Ford Aerostar last?
A well-maintained Ford Aerostar typically lasts 250,000–300,000+ miles. It's exceptionally durable — with routine maintenance many owners report 250k+ on the original powertrain. Its ForCar Reliability Score is 3.5/5.
Check your Ford Aerostar’s VIN — history, recalls & specs
Title records, open recalls, build details and paint code — straight from the VIN. Free.
Check this Aerostar’s VIN free →All Ford Aerostar model years
A year-by-year snapshot of the Ford Aerostar — recalls, best EPA fuel economy and NHTSA safety. Tap a year for full details.
| Year | Recalls | Best MPG | Safety |
|---|---|---|---|
| 1997 Aerostar | 5 recalls | — | — |
| 1996 Aerostar | 6 recalls | — | — |
| 1995 Aerostar | 7 recalls | — | — |
| 1994 Aerostar | 5 recalls | — | — |
| 1993 Aerostar | 4 recalls | — | — |
| 1992 Aerostar | 5 recalls | — | — |
| 1991 Aerostar | 4 recalls | — | — |
| 1990 Aerostar | 7 recalls | — | — |
| 1989 Aerostar | 6 recalls | — | — |
| 1988 Aerostar | 5 recalls | — | — |
| 1987 Aerostar | 5 recalls | — | — |
| 1986 Aerostar | 9 recalls | — | — |
| 1985 Aerostar | 0 | — | — |
| 1984 Aerostar | 0 | — | — |
Recalls = NHTSA campaigns that year · MPG = best EPA combined · Safety = NHTSA overall stars (tested years).
Frequently asked questions
What are the worst years for the Aerostar?
By owner-complaint volume, 1993, 1992, 1994 drew the most reports. 1984, 1985, 1997 have the cleanest records.
How many recalls does the Aerostar have?
68 recorded NHTSA recalls across 1984–1997. Always check open recalls by your VIN.
How many miles does a Aerostar last?
A well-maintained Aerostar typically reaches 200,000–300,000 miles with regular maintenance.
Is the Aerostar reliable?
Our ForCar Reliability Score for the Aerostar is 3.5/5, based on NHTSA safety, recall history and complaint severity.
What's the Ford Aerostar warranty?
New Ford models carry a 3 years / 36,000 miles basic (bumper-to-bumper) warranty and a 5 years / 60,000 miles powertrain warranty. Coverage can vary by model year and market — confirm with a Ford dealer.
Where is the Ford Aerostar made?
The assembly plant is encoded in the VIN — the 11th character. Decode your Aerostar's VIN above to see exactly where it was built; Ford may build it at more than one plant depending on the year.
How much ground clearance does the Aerostar have?
Ground clearance varies by trim and drivetrain — AWD/4WD versions often sit higher. Decode your VIN or check the specific trim for the exact figure.