The Ford Aerostar has 26 NHTSA recall campaigns on record covering 1986–1997. On average a defect was admitted 4.71 years after the car was built, the slowest took 21 years. The most recalled system is Fuel System, Gasoline (5 campaigns). Owners also filed 1,723 complaints on this model — see what breaks.
What was recalled on the Ford Aerostar
Grouped by system. Open any row for the campaigns themselves — what failed, what it risks and how the dealer fixes it, straight from the NHTSA filing.
Fuel System, Gasoline 5 Read
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
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
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
Electrical System 4 Read
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
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
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
Power Train 3 Read
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
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
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
Equipment 3 Read
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
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
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
Service Brakes, Hydraulic 2 Read
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
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
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
Seat Belts 2 Read
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
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
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
Seats 2 Read
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
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
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
Vehicle Speed Control 1 Read
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, Air 1 Read
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
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
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
Latches/locks/linkages 1 Read
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
How long a defect stays unadmitted
Campaign numbers encode the year of the announcement, so each recall on this model can be dated against the car it applies to.
| Measure | Value |
|---|---|
| Average gap before admission | 4.71 years |
| Slowest campaign | 21 years |
| Admitted 5+ years later | 42.4% |
| Campaigns on record | 26 |
Which Aerostar years were recalled most
Campaigns per model year. A year with more campaigns is not automatically worse — it may simply have sold in far greater numbers.
| Model year | Campaigns | Most recalled system |
|---|---|---|
| 1997 | Vehicle Speed Control | |
| 1996 | Service Brakes, Hydraulic | |
| 1995 | Service Brakes, Hydraulic | |
| 1994 | Service Brakes, Hydraulic | |
| 1993 | Service Brakes, Hydraulic | |
| 1992 | Service Brakes, Hydraulic | |
| 1991 | Seat Belts | |
| 1990 | Service Brakes, Hydraulic | |
| 1989 | Seats | |
| 1988 | Electrical System | |
| 1987 | Fuel System, Gasoline | |
| 1986 | Fuel System, Gasoline |
Check your own car
A campaign applies to a range of production, not to every car of the model. The only way to know whether yours is affected — and whether the repair was already done — is by VIN.
| Step | What you get |
|---|---|
| Enter the VIN above | Open campaigns for that exact vehicle, straight from NHTSA |
| Check the repair status | Whether the free fix has already been carried out on this car |
| Book at any franchised dealer | Recall work is free regardless of age, mileage or owner |
Go deeper
A campaign covers a production range. Yours is one car.
- Check whether this exact VIN is affected — and whether the fix was done
- Alerts if a new campaign lands on a car in your garage
- Full research report as a PDF you can hand to a mechanic
- Decode a whole list of VINs at once
- No ads, on every page
- No ads, no tracking — and much more
Frequently asked questions
How many recalls does the Ford Aerostar have?
26 NHTSA campaigns on record, covering 1986–1997. Not every campaign applies to every car — coverage is by production range, so check your VIN.
Is recall work free?
Yes. Safety recall repairs are free at any franchised dealer regardless of the car's age, mileage or how many owners it has had. That is a federal requirement, not a courtesy.
How do I know if my Aerostar still has an open recall?
Enter its VIN above. We show campaigns that apply to that exact vehicle and whether the repair has already been recorded as done.
Why did a defect take years to be recalled?
On this model the average gap between the car being built and the defect being admitted is 4.71 years, and the slowest campaign came 21 years later. Defects usually surface as they accumulate in the field: complaints pile up, an investigation opens, and only then is a campaign issued.