1994 Ford Aerostar

Fatalities reported

Owners filed 257 complaints about this vehicle with federal regulators, most often about the electrical system. It has been recalled 5 times.

Not among the Ford Aerostar years to avoid. Which Ford Aerostar years to avoid →

Most common 1994 Ford Aerostar problems

55 of the 257 complaints (21%) are about the electrical system.

ComponentReportsCrashesFiresInjuries
Air Bags · airbags22
201
Electrical System › Ignition › Switch21
040
Air Bags › Frontal · airbags14
1308
Power Train › Automatic Transmission › Lever and Linkage › Column Shift · transmission11
011
Power Train › Automatic Transmission · transmission11
011
Service Brakes, Hydraulic › Antilock/Traction Control/Electronic Limited Slip · brakes10
100
Electrical System › Wiring › Front Underhood8
050
Electrical System › Wiring7
040
Steering › Steering Wheel/Handle Bar6
100
Power Train › Transfer Case (4-wheel Drive) · transmission6
000

5 safety recalls

Part 573 reports
Service Brakes, Hydraulic06E022000
Filed Mar 13, 20067,440 vehiclesBrake Parts, Inc.

Defect. 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.

Remedy. 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.

Electrical System › Wiring › Front Underhood99V028000
Filed Feb 9, 199923,097 vehiclesFord Motor Company

Defect. 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.

Remedy. 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 › Switch99V029000
Filed Feb 9, 1999762,201 vehiclesFord Motor Company

Defect. 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.

Remedy. 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 › Rotor98E010000
Filed Apr 8, 199823,500 vehiclesAimco Products Inc.

Defect. 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.

Remedy. 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)97V204000
Filed Nov 13, 199775,000 vehiclesFord Motor Company

Defect. 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.

Remedy. DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

All 5 campaigns on file, newest first.

What owners reported

Newest filings
Air Bags
Filed Oct 25, 2017GA

AIRBAG (CODE 13 AND 51) LIGHTS FLASHING

Electrical SystemFire
Filed Aug 12, 201393,000 milesVA

VAN HAD BEEN DRIVEN FOR APPROXIMATELY TWO HOURS OR SO, AROUND THE LOCAL CITY COMMUNITIES. VAN HAD BEEN PARKED FOR APPROXIMATELY FIVE MINUTES, WHEN NEIGHBORS NOTIFIED ME OF FIRE. INTENSE FIRE WAS COMING FROM DRIVER'S SIDE/WINDSHIELD/IGNITION/FRONT SEAT AREA, EVENTUALLY CONSUMING ENTIRE INTERIOR OF VAN. NORFOLK FIRE DEPARTMENT RESPONDED WITHIN FIVE MINUTES, OR SO, STATION ONLY ABOUT 150 YARDS FROM MY RESIDENCE. FIRE WAS EXTINGUISHED WITHIN FIVE MINUTES OR SO, BUT THE VAN WAS COMPLETELY CONSUMED BY FIRE AND TOTALLY DESTROYED BY THEN. VAN WAS JUNKED/SALVAGED. PAID ONLY $100.00 FOR SALVAGE/JUNK/TOWING, ETC. PRIOR TO THIS INCIDENT, I HAD NO PROBLEMS WITH MY VAN. VAN ONLY HAD 93000 MILES. HAD PURCHASED NEW FROM FREEDOMS FORD IN NORFOLK, VA. INFORMED BY ASSOCIATE THAT I SHOULD REPORT THIS "FIRE HAZARD/PROBLEM," BECAUSE OTHER 1994 FORD AEROSTAR VANS HAVE EXPERIENCED SIMILAR "FIRE PROBLEMS/INCIDENTS/REPORTS," AND THE LIKE. PLEASE INFORM ME OF WHAT ACTIONS I NEED TO TAKE TO RECOUP SOME MONETARY VALUE FOR THIS "FIRE INCIDENT," ETC. MY VEHICLE PAPERWORK WAS BURNED/DESTROYED IN THE FIRE. HOWEVER, THE NORFOLK FIRE DEPARTMENT DID MAKE AN "OFFICIAL FIRE REPORT/RECORD" OF THE INCIDENT, ETC. ALSO, MINOR DAMAGE WAS DONE TO THE ALUMINUM SIDING OF MY HOUSE FROM THE VEHICLE FIRE. *TR

Electrical System
Filed Jun 13, 2012FL

HAD THE CLOCK RING REPAIRED (YEAR 2000)DUE TO THE AIRBAG LIGHT STAYED ON. NOW THE AIRBAG LIGHT STAYS ON ,THERE IS NO HORN AND THE CRUISE CONTROL DOESNT WORK. THERE HAS TO BE A RECALL FOR THIS SAFETY PROBLEM. *TR

Fuel System, Gasoline
Filed Jul 8, 2009CA

WE WERE BEGINNING TO EXPERIENCE LOSS OF POWER. THE FUEL PUMP AND FILTER WAS CHANGED. WE ARE STILL GETTING INTERMITTENT LOSS OF POWER, BUT WHAT MY CONCERN IS THAT I SAW A RECALL ON NHTSA: 99V028000. I WAS MADE AWARE OF THIS RECALL WHEN I VIEWED AN EPISODE OF COPS WHERE AN AEROSTAR'S ELECTRICAL SYSTEM CAUSED A FIRE IN THE ENGINE COMPARTMENT. I CALLED FORD IN TEMECULA CALIF AND NOW THEY HAVE NO RECORD OF ANY RECALLS FOR THIS YEAR OF AEROSTAR 1994 I DO HAVE KIDS AND I WOULD LIKE TO KNOW WHAT SAFETY MATTERS REMAIN ON THIS VAN. *TR

Air Bags
Filed Jul 5, 2008120,000 milesIA

ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION. *TR

Suspension › Rear › Springs › Coil Springs
Filed Feb 12, 2008120,000 milesPA

FRONT COIL SPRINGS SNAPPED, HAD TO REPLACED WITH READING SPRING WORKS, THEY HAD TO SEND THE SPECKS TO CHICAGO. MY FORD AERO STAR 4 WHEEL DRIVE & 4.0 V6 IS NOT AVAILABLE FROM AFTER MARKET. THE ONLY OPTION IS TO BUY NEW OR USED FORD SPRINGS WHICH ARE MADE IN CHINA. THE LOCAL FORD DEALER ADMITS REPLACING COIL & LEAF SPRINGS ON SEVERAL MODELS. MIDAS WAS SO BUSY REPLACING FORD SPRINGS, THEY COULD NOT SET UP AN APPOINTMENT TO INSTALL SPRINGS EVEN IF I HAD THE SPRINGS. *TR

Electrical System › IgnitionFire
Filed Feb 6, 2008110,000 milesCA

CAR WAS PARKED IN DRIVEWAY, UNTOUCHED, FOR AT LEAST 24 HOURS. FIRE ERUPTED ABOUT 7:00 AM. FLAMES WERE COMING THROUGH THE DRIVERS SIDE WINDSHIELD. SEEMED TO BE ELECTRICAL IN NATURE. CAR IS A TOTAL LOSS. CAR IS COMPLETELY ORIGINAL (NO ELECTRIC ALTERATIONS). CAR HAD BEEN TO THE DEALER WITHIN THE LAST 2 YEARS SO ANY RECALL WORK SHOULD HAVE BEEN DONE. *TR

Steering › Steering Wheel/Handle Bar
Filed Sep 17, 2006200,000 milesCA

THE SEAMS IN THE STEERING WHEEL OOZE BLACK GOO AND FORM DIME SIZED POOLS AROUND THE INSIDE CENTER WHERE THE AIRBAG IS PACKED ...THE DEALER SAID JUST BUY A COVER BUT IT CONTINUES TO LEAK AS A NEW STEERING WHEEL WOULD BE VERY COSTLY DUE TO AIRBAG, I WORRY IF AIRBAG WILL DEPLOY CORRECTLY IN A CRASH. *JB

Electrical System › Wiring › Front UnderhoodFire
Filed Feb 1, 2006100,000 milesCA

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

Tires › Tread/Belt
Filed Nov 23, 2005TX

1994 FORD AEROSTAR TIRE BLEW (FIRESTONE DAYTON QUADRA SE). *TS THE TREAD SEPARATED FROM THE TIRE. *NM

Air Bags
Filed Oct 21, 2005125,000 milesOH

DT: CONTACT STATED THAT THE AIR BAG LIGHT ON THE DASHBOARD FLASHED ON AND OFF. THE CRUISE CONTROL AND THE HORN WILL NOT WORK. THE PROBLEM STARTED WITHOUT WARNING. HE WAS TOLD BY THE DEALER THE AIR BAG WILL NOT WORK AS LONG AS THE LIGHT ON THE DASHBOARD WAS ON. ALSO, THE DEALER TOLD HIM HE HAD A BROKEN WIRE IN THE STEERING WHEEL. HE HAS NOT HAD IT REPAIRED YET. THE AIR BAG PROBLEM WAS NOT COVERED UNDER WARRANTY OR RECALL. THEREFORE, E THE MANUFACTURER WILL OFFER NO FREE REMEDY. *AK

Visibility › Windshield Wiper/Washer › Switch/Wiring
Filed Nov 13, 2004105,800 milesOR

WINDSHIELD WIPERS FAIL TO FUNCTION UNLESS LIGHTS ARE ON HIGH BEAM OR WASHER SEQUENCE IS STARTED. *JB

Air BagsCrash1 injured
Filed Aug 10, 2004137,000 milesMO

CONSUMER'S VEHICLE WAS INVOLVED IN A HEAD ON COLLISION WHILE GOING THROUGH AN INNER SECTION BETWEEN 25-30 MPH. UPON IMPACT, DRIVER'S SIDE AIR BAG FAILED TO DEPLOY. DRIVER SUSTAINED CHEST INJURIES FROM THE SEAT BELT. MANUFACTURER WANTED TO SEND A FACTORY REPRESENTATIVE TO INVESTIGATE THE CAUSE OF THE FAILURE.*AK

Electrical System › Horn
Filed Mar 10, 2004CA

THREE DAYS AFTER I HAVE THE VANS WIREING DONE BECAUSE OF A RECALL, MY HORN STOPPED WORKING AND THE AIR BAG LIGHT STARTED FLASHING AND MY BRAKE LIGHTS STARTED STAYING ON. I CALLED JIM WILSON FORD WHO DID THE REPAIRS I WAS TOLD BY THE HEAD MAN AT THE DEALERSHIP THAT IT WAS NOT THERE FALT AND I WOULD HAVE TO PAY TO HAVE IT FIXED. EVERYTHING WORKED FINE UNTIL THEY DID THE RECALL WORK.*AK

Steering › Column
Filed Nov 12, 2003MI

THE ACCESSORIES IN MY DASH AND STEERING COLUMN ARE SHORTING OUT, AND I SAW THAT THERE WAS A RECALL ON THAT. THE PROBLEM IS THAT THE RECALL DOES NOT INCLUDE WHEN MY VAN WAS MADE. I DON'T CARE WHY I JUST WANT TO BE ABLE TO DRIVE MY KIDS TO SCHOOL AND BACK AND NOT HAVE MY VAN CATCH ON FIRE. WE HAVE BEEN THROUGH THAT ALREADY WITH A DIFFERENT VEHICLE. ALSO, THE FUEL PUMP IS ACTING UP ANDI WAS TOLD IT SEEMS AS THOUGH IT IS SHORTING OUT!. AGAIN NOT THE RIGHT MONTH BUT I HAVE THE SAME PROBLEMS SO THE WAY I SEE IT IS THAT FORD MESSED UP AND SHOULD FIX THE PROBLEM, PERIOD. I PLAN TO CONTINUE TO FOLLOW THIS AND TO RIGHT TO MY LOCAL GOVERNMENT. THE SAFETY OF MY FAMILY SHOULD NOT BE DETERMINED AS TO HOW LOUDLY PEOPLE COMPLAIN, IT SEEMS AS THOUGH THE VEHICLES THAT ARE COVERED WERE THE GREATEST RISK TO THE COMPANY. *LA

Structure › Frame and Members
Filed Oct 23, 2003109,089 milesNY

SPARE TIRE FELL-OFF, WITH OUT ANY WARNING, FROM ITS MOUNTING UNDERNEATH THE VAN. WE WERE LUCKY THAT THIS HAPPENED IN A PARKING LOT AND THE VAN WE JUST PARKED. THERE WAS A RATTLE DURING DRIVING, BUT STOPPED WHEN GOING SLOW OR STOPPED. *LA

Air Bags › FrontalCrash
Filed Sep 12, 2003IN

THE VEHICLE HIT A TREE, AND THE AIR BAGS FAILED TO DEPLOY. *JB THE CONSUMER SLID ON A PATCH OF ICE AND HIT A TREE IN CENTER OF THE BUMPER. *SCC *JB

Power Train › Automatic Transmission
Filed Jul 8, 2003OH

CONSUMER STATES THAT THE GEAR SHIFT CAN BE PUSHED DOWN WITHOUT APPLYING THE BRAKE. DEALER NOTIFIED.*AK

Air Bags › FrontalCrash1 injured
Filed Jun 25, 200390,000 milesGA

CONSUMER STATES THAT A FRONT COLLISION OCCURRED AND THE AIR BAG DEPLOYED ON HER FACE. SINCE THEM SHE HAD A RESPIRATORY PROBLEM. *AK

Seat Belts › Front › Buckle Assembly
Filed May 29, 2003100,000 milesFL

DRIVER'S SEATBELT WILL NOT STAY FASTENED. CAUSE IS UNKNOWN. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK

Suspension › Rear › Springs
Filed May 15, 2003147,000 milesIN

FAILURE OF RIGHT REAR COIL SPRING CAUSING EXPLOSIVE TIRE DEFLATION. FAILURE OCCURRED AT THE END OF THE SPRING COATING- CORROSION PRESENT, BUT HIDDEN BY FACTORY COATING OF SPRING. *JB

Power Train › Automatic Transmission
Filed May 5, 2003NJ

AUTOMATIC TRANSMISSION FAILURE - TRANSMISSION FALLS OUT OF GEAR. *JB

Tires
Filed Mar 25, 2003CA

THE RIGHT REAR TIRE BLEW OUT. *JB

Air BagsCrash
Filed Feb 25, 200372,000 milesVA

DATE IS APPROXIMATE. 1994 FORD AEROSTAR REAR ENDED AT STOP LIGHT HARD ENOUGH TO BREAK 7X19 CABLE HOLDING SPARE TIRE, AND SEND VEHICLE INTO CAR IN FRONT OF IT WITH ENOUGH FORCE TO BREAK RADIATOR AND AC RADIATOR. AIR BAG DID NOT DEPLOY. APPROXIMATLY 3 MONTHS AFTER BACK FROM REPAIRS, THE AIRBAG LIGHT STARTED BLINKING OCCASIONLY. THIS CONTINUED GETTING WORSE UNTIL IT BLINKED CONSTANTLY, ALSO THE HORN WAS INTERMITTENTALY OPERATIONAL. I CHECKED YOUR "SEARCH COMPLAINTS" SECTION AND SEE SEVERAL PEOPLE HAVE HAD THE SAME PROBLEM EVEN WITHOUT THE ACCIDENT. I HAD THE VEHICLE REPAIRED AND IT WAS THE CLOCK SPRING AS SEVERAL PEOPLE STATE IN THE COMPLAINTS SECTION. IN FACT THIS MUST BE COMMON DUE TO WHEN I CALLED THE DEALERSHIP THAT DID THE ORIGINAL REPAIRS THEY DIDN'T EVEN LISTEN TO ALL THE INFORMATION ON THE PROBLEM AND SAID "IT SOUNDS LIKE THE CLOCK SPRING AND TAKES ABOUT 2 HOURS TO REPAIR." THEN QUOTED A PRICE, ONLY MISSING THE PRICE QUOTE BY THE AMOUNT OF TAX ADDED TO THE BILL! PLEASE RESEARCH THIS, IF NOTHING ELSE LOOK AT YOUR OWN SYSTEM UNDER AIRBAGS, HORN, AND SPEED CONTROLS! DOESN'T TAKE A BEAN COUNTER TO SEE THERE IS A PROBLEM WITH THIS "SAFETY" SYSTEM!!!!!!!*JB

Electrical System › Wiring › Interior/Under Dash
Filed Feb 24, 2003FL

THE WIRING HARNESS IN MY STEERING COLUME IS DEFECTIVE. THIS WILL BE THE SECOND TIME IN 6 YRS THAT THIS HAS HAD TO BE REPLACED. THE HARNESS CONTROLLS THE AIRBAGE, HORN AND CRUISE CONTROLL. ALSO THE IGITION SWITCH IS FAULTY, THE KEY CAN BE REMOVED WHILE THE VEHICLE IS RUNNING

Steering › Column
Filed Dec 31, 200270,000 milesOH

CONSUMER WAS PULLING INTO A PARKING SPACE. SUDDENLY THEY WERE UNABLE TO STEER VEHICLE OR CHANGE GEARS. CONSUMER HAD VEHICLE TOWED TO A DEALERSHIP, WHO INDICATED THAT THIS WAS CAUSED BY A PART BRAKING IN THE STEERING COLUMN. PLEASE PROVIDE MORE DETAILS. TS

Electrical System › Wiring › Interior/Under DashFire
Filed Sep 30, 2002TN

CONSUMER STATES THAT A FIRE STARTED UNDER THE DASH WHILE DRIVING. LOCAL FIRE DEPARTMENT ARRIVED TO EXTINGUISH THE FIRE. NLM

Fuel System, Gasoline › Fuel Injection System1 injured
Filed Jul 29, 2002IL

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

Power Train › Automatic Transmission › Lever and Linkage › Column Shift
Filed May 23, 2002PA

THE TRANFER CASE HEATED UP AND SEPARATED FROM THE TRANSMISSION IN THE PROCESS THE TRANSMSSION WAS CRACKED AND REPLACED, THREE TIMES BY THE MANUFACTURER.*JB THE TRANSFER CASE WAS RECALLED (97V-204) BY THE MANUFACTURER AFTER THE TRANSMISSION HAD FAILED THREE TIMES. *YH

Equipment › Electrical
Filed May 20, 2002CA

WHEN PRESSING CIGARETTE LIGHTER IN, ONCE IT GETS HOT, IT POPPED OUT ONTO THE FLOOR. CONSUMER FELT THAT IF THIS HAPPENED IN TRAFFIC DRIVER WOULD HAVE TO TAKE EYES OFF THE ROAD TO FIND LIGHTER IN ODER TO PREVENT A VEHICLE FIRE. THIS COULD CAUSE AN ACCIDENT. *AK

Electrical System › Wiring
Filed Mar 22, 2002LA

CONSUMER SAW SMOKE COMING FROM STEERING COLUMN, THEN HEARD A POP WITH A CLOUD. CONSUMER HAD NO LIGHTS, AND STATED THAT SMOKE WAS COMING FROM STEERING COLUMN AND FILLED THE CAR. VEHICLE WAS TOWED TO DEALER, AND THEY STATED A GROUND WIRE BURNED, AND CAUSED THE SMOKE.*AK *YH

Electrical System › Wiring › Front UnderhoodFire
Filed Mar 21, 2002NY

THE VEHICLE JUST WENT UP IN FLAMES. *AK

Structure › Body › Hatchback/Liftgate › Support Device/Strut1 injured
Filed Feb 15, 2002CD

WHILE THE LIFT GATE WAS IN THE UP POSITION, ONE STUD SNAPPED OFF AT THE FRAME, DROPPING THE LIFT GATE ON THE BACK OF CONSUMER'S HEAD AND SHOULDERS. *TT

Power Train › Axle Assembly
Filed Nov 30, 2001MD

REAR PASSENGER SIDE WHEEL CAME OFF WHILE CONSUMER WAS DRIVING UP A SLIGHT INCLINE. DEALER HAS BEEN CONTACTED, AND INFORMED CONSUMER THAT AXLES WERE DEFFECTIVE. PLEASE PROVIDE FURTHER DETAILS. *AK

Interior Lighting
Filed Nov 27, 2001MD

INTERIOR LIGHTS REMAINED ILLUMINATED AFTER THE VEHICLE WAS SHUT OFF, CONSUMER HAD TO DISCONNECT ENGINE BATTERY FOR THE LIGHTS TO GO OUT. DEALER HAS YET TO BE CONTACTED, PLEASE PROVIDE FURTHER DETAILS.*AK

Air Bags
Filed Nov 27, 2001AR

AIR BAG LIGHT ON THE INSTRUMENT PANEL WILL ILLUMINATE ERRATICALLY, THEN GO OFF WHILE OPERATING VEHICLE AT ANY SPEED. ALSO, HAS EXPERIENCED FAILURE OF CRUISE CONTROL AND HORN. DEALERSHIP HAS NOT EXAMINED VEHICLE TO DETERMINE A CAUSE FOR THIS PROBLEM. PLEASE PROVIDE ANY ADDITIONAL INFORMATION / DOCUMENTATION.*AK

Air Bags
Filed Nov 27, 2001AK

AFTER FORD RECALL FOR REPLACEMENT OF WIRING IN STEERING COLUMN, THE AIRBAG LIGHT BEGAN BLINKING IN A 3/2 PATTERN. THE CRUISE CONTROL AND HORN BOTH CEASED FUNCTION. INDICATES A CLOCKSPRING FAILURE MEANING THAT THE AIRBAG, CRUISE CONTROL AND HORN ARE INOPERATIVE. ALSO, THE REAR LIFTGATE SUPPORTS ARE FIXED TO THE FRAME WITH SMALL STUDS. WITH THE LIFTGATE OPEN, ONE OF THESE STUDS BROKE SENDING THE LIFTGATE CRASHING ONTO OWNER'S HEAD AND NECK.

Power Train › Automatic Transmission › Park/Neutral Start Interlock Switch1 injured
Filed Nov 26, 2001TN

AFTER CONSUMER PARKED VEHICLE AND TOOK KEY OUT OF IGNITION, WHILE GETTING OUT OF VEHICLE, IT STARTED ROLLING BACKWARD, CONSUMER WAS CAUGHT BY DOOR, BRUISED BADLY. VEHICLE WAS STOPPED BY A TREE. SINCE IT ROLLED VERY SLOWLY THERE WAS NO DAMAGE. VEHICLE NOT TAKEN TO DEALER YET. *AK *SLC

Air Bags
Filed Sep 17, 2001NJ

AIRBAGS DEACTIVATED. ALSO, VEHICLE HAD NO HORN. AIRBAG LIGHT WAS COMING ON AND OFF.CONTACTED DEALER, AND DEALER STATED CLOCK SPRING WAS DEFECTIVE.*AK

Tires › Tread/Belt
Filed Sep 6, 2001KY

WHILE HAVING TIRES BALANCED AND ROTATED, CONSUMER WAS INFORMED THAT TIRES WERE SHOWING SIGNS OF TREAD SEPARATION, THE TIRE DEALER EXCHANGED THE SET OF GENERAL/CONTINTAL TIRES (P215/70 R14 AMER1 GYS) WITH ANOTHER SET, HOWEVER ON JUNE 26, 2001 WHILE DRIVING ONE OF THE REPLACEMENT TIRES BEGAN TO EXPERIENCE TREAD SEPARATION, VEHICLE WAS TAKEN INTO TIRE DEALER, AND CONSUMER WAS INFORMED THAT THE WARRANTY WAS VOID ON THE TIRE BECAUSE THE TIRE HAD BEEN REPAIRED IN THE PAST DUE TO A NAIL PUNCYTURE, AFTER THE CONSUMER COMPLAINED THE TIRE DEATLER SETTLED WITH THE CONSUMER.*JB

Power Train › Automatic Transmission
Filed Jul 1, 2001AL

WHILE DRIVING IN THE SMOKY MOUNTAINS IN NC THE TRANSMISSION OVERHEATED AND POURED OUT TRANSMISSION FLUID. THE VAN BEGAN TO SMOKE AND I PULLED OVER IN A DANGEROUS PLACE. I DECIDED TO TURN AROUND (ALSO IN DANGEROUS PLACE) I WENT BACK TO CHEROKEE, NC AND A MECHANIC SAID THIS WAS A COMMON PROBLEM FOR AREOSTARS. HE SAID MANY PEOPLE GET RIPPED OFF BY UNTRUSTWORTHY MECHANICS. WHILE TRAVELING OVER THE MOUNTAINS WE SAW THREE OTHER AREOSTARS WITH THE SAME PROBLEM. TWO WERE BEING TOWED BY WRECKERS. AREOSTAR OWNERS NEED TO BE NOTIFIED OF THIS PROBLEM. THAT THE TRANSMISSION WILL OVERHEAT UNDER A LOAD AND TRANSMISSION FLUID WILL BE LOST. WE WERE VERY UPSET BY THIS AND OUR VACATION WAS RUINED. BUT BECAUSE WE FOUND A GOOD MECHANIC WE WERE NOT RIPPED OFF. I CANNOT SAY THE SAME ABOUT THE OTHER VANS THAT WE SAW BEING TOWED FROM THE MOUNTAIN AND WE WERE ONLY THERE FOR A COUPLE OF HOURS AND SAW THREE OTHERS IN TROUBLE.*AK

Electrical System › Wiring › Front UnderhoodFire
Filed Jun 27, 2001NC

VHEHICLE CAUGHT FIRE NEAR CENTER OF MOTOR BEHIND WHERE YOU PUT IN THE OIL. VEHICLE WAS TAKEN TO LOCAL FORD DEALER FOR RECALL ON THE ACCESSORY POWER CIRCUIT. I RECEIVED A LETTER IN THE MAIL ABOUT THE SWITCH RECALL. THE 94-95 MODELS WHERE ALSO RECALLED DUE AN ELECTRICAL SHORT OUT AT FUEL PUMP RESULTING IN POWER LOSS AND FIRE. I BELIVE THIS TO BE WHAT HAPPENED TO MY VAN.I WAS NOT NOTIFIED OF THIS RECALL, NIETHER WAS I INFORMED OF IT WHAN I TOOK THE VAN IN FOR THE OTHER RECALL ON THE SWITCH. CAN YOU TELL ME WHAT TO DO FROM HERE? SHOULD I GO TO THE LOCAL FORD DEALER? *AK

Electrical System › Wiring › Interior/Under Dash
Filed Jun 25, 2001WV

NO SUMMARY LISTED FOR ABOV EVEHICLE. *AK

Engine and Engine Cooling › Engine
Filed May 23, 2001OH

VEHICLE EXPERIENCING PROBLEM WITH LOSS OF COOLANT AND OVERHEATING WHILE DRIVING. INDEPENDENT MECHANIC INFORMED OF A HEAD GASKET FAILURE. VEHICLE WAS NOT COVERED UNDER MANUFACTURER'S EXTENDED WARRANTY. FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK

Latches/Locks/Linkages › Doors › Latch
Filed May 8, 2001CA

SLIDING DOOR WOULD JAM AFTER BEING CLOSED. CANNOT USE KEY TO OPEN. SOMETIMES WHILE DRIVING, EITHER UP A HILL OR HITTING A BUMP, SLIDING DOOR WOULD OPEN WITHOUT WARNING. HAVE TAKEN TO DEALERSHIP, MECHANIC GAVE AN ESTIMATE OF COST OF NEW DOOR REPLACEMENT.*AK *JB

Air Bags › Frontal
Filed May 1, 2001MI

THIS VEHICLE HAS NEVER BEEN IN AN ACCIDENT THAT I AM AWARE OF AND OVER A YEAR AGO WHILE DRIVING MY AIR BAG LIGHT POPED ON. WHEN I GOT HOME I CALLED OUR LOCAL FORD GARAGE & THEY INFORMED ME THAT THE AIR BAG NO LONGER WAS WORKING. I FEEL IF YOU BUY THE VEHICLE WITH THE AIR BAG YOU EXSPECT IT TO BE THERE IN CASE OF AN ACCIDENT. WHAT IS THE POINT IN HAVING ONE IF IT CANNOT LIVE UP TO THE LIFE OF YOUR VEHICLE. THE PART IS ONLY 150.00 BUT I REFUSE TO PAY FOR SOMETHING TO BE FIXED IF IT WAS NEVER DEPLOYED IN THE FIRST PLACE. THIS IS SUPPOSE TO BE A SAFTY FEATURE BUT IT IS NOT VERY SAFE IF IT NO LONGER WORKS. *AK

Engine and Engine Cooling › Engine
Filed Apr 25, 2001IL

WHILE DRIVING ON INTERSTATE VEHICLE STARTED TO LOOSE POWER AND THEN CEASED TO FUNCTION ALTOGETHER, VEHICLE WAS TOWED INTO DEARLERSHIP AND CONSUMER WAS ADVISED THAT THE ENGINE BLOCK WAS CRACKED AND THAT THE ANTI-FREEZE WAS GETTING INTO THE ENGINE, CONSUMER PURCHASED A REBUILT ENGINE. *JB

Fuel System, Gasoline › Storage › Tank AssemblyFire3 injured
Filed Apr 22, 2001NV

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.

Electrical System › Ignition
Filed Apr 18, 2001CA

VEHICLE IS STALLING AT ANY SPEED, AND ANY TIME. DEALER STATED IGNITION MODULE NEEDED TO BE REPLACED. *AK

Air Bags › FrontalCrash
Filed Apr 2, 2001CA

VEHICLE WAS INVOLVED IN A FRONTAL COLLISION AT45MPH. UPON IMPACT, AIRBAGS DID NOT DEPLOY.*AK

Complaints 1-50 of 257, newest first, reproduced as filed.

Across model years

Worst on record: 1993
YearComplaintsRecallsFiresDeathsAssessment
20006000Routine
19997001Fatalities reported
19984010Routine
199763520Routine
1996104640Routine
19951577180Routine
1994 — this page2575284Fatalities reported
19933744380High concern
19923175304Fatalities reported
19912234691Fatalities reported
19901957570High concern

Compare every Aerostar year →

Reading this record

4 deaths reported in complaints filed with NHTSA.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Recall repairs are free for as long as the recall stands. Check whether a specific car still has open work at NHTSA's VIN lookup.

Most recent recall on file: Mar 13, 2006. Source: NHTSA Office of Defects Investigation.