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1991 Ford Aerostar

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 1991 Ford Aerostar do not stand out strongly from the model-year median of 135.5.

About this comparison →
223Owner complaints

Model-year median: 135.5

3Recall campaigns

View recall details →

2Investigations

View investigation details →

How this year compares

Owner complaints by model year

Other model years Selected year
177
1988260
1989195
1990223
1991317
1992374
1993257
1994
Compare all Aerostar years →

Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

Electrical System
67Power Train
49Service Brakes, Hydraulic
31Vehicle Speed Control
23Equipment
14
All reported categories
Engine And Engine Cooling
13Structure
9Steering
7Latches/locks/linkages
6Visibility
6Suspension
5Fuel System, Gasoline
4Exterior Lighting
3Parking Brake
3Seats
3Tires
3Unknown Or Other
3Seat Belts
2

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

Limited mileage data: 2 of 223 reports include usable mileage. There isn’t enough coverage to show a useful chart.

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 67 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 31 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

23 crash reports68 fire reports14 injury reports

Engine And Engine Cooling complaints

13 reports
Clear category filter
Mileage unknown · Jan 15, 2004
Engine And Engine CoolingPower TrainUnknown Or Other

1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS

NHTSA ODI #10069585

Mileage unknown · Nov 21, 2001
Engine And Engine Cooling

WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION. *AK

NHTSA ODI #899347

Mileage unknown · Dec 6, 2000
Engine And Engine Cooling

THE FLYWHEEL HAS BEEN REPLACED 5 TIMES. IT CONTINUES TO TEAR APART NEAR WHERE IT IS BOLTED ON. THIS IS AN ONGOING PROBLEM THAT WE CANNOT SOLVE. MY MECHANIC CANNOT DETERMINE WHY THIS CONTINUES TO HAPPEN. *AK

NHTSA ODI #737383

Mileage unknown · Oct 1, 1998
Engine And Engine CoolingFire

BEING PARKED FOR ABOUT A HALF AN HOUR THE VEHICLE HAD A SMALL EXPLOSION AND CAUGHT ON FIRE ON THE PASSENGER'S SIDE/ UNDERNEATH THE VEHICLE AND THROUGH THE DASH PANEL. NO PRIOR PROBLEMS WITH THE VEHICLE. CAUSE UNKNOWN. PLEASE PROVIDE DETAILS. *AK

NHTSA ODI #828417

Mileage unknown · Nov 25, 1997
Engine And Engine CoolingFire

WITH ENGINE RUNNING AND AC ON DRIVER NOTICED SMOKE RISING FROM GRILL ABOVE HOOD.

NHTSA ODI #525392

Mileage unknown · Sep 10, 1997
Engine And Engine Cooling

OXYGEN SENSOR, PCV VALVE FAILED.

NHTSA ODI #521979

Mileage unknown · Nov 6, 1996
Engine And Engine CoolingFire

VEHICLE FIRE PRIOR TO RECALL.

NHTSA ODI #510652

Mileage unknown · May 6, 1996
Engine And Engine Cooling

RADIATOR FAN BLADE HAS STRESS CRACKS. *SD

NHTSA ODI #504334

Mileage unknown · Dec 7, 1995
Engine And Engine Cooling

ENGINE HEAD WAS CRACKED AND HAD TO BE REPLACED. TT

NHTSA ODI #976268

Mileage unknown · Oct 27, 1995
Engine And Engine CoolingFire

ENGINE COMPARTMENT FIRE. TT

NHTSA ODI #487586

Official recalls

3

96V071000 · Electrical System:ignition

Apr 25, 1996

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence & remedy

Consequence: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

91V189000 · Power Train:automatic Transmission

Nov 4, 1991

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Consequence & remedy

Consequence: 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.

Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

91V164000 · Seat Belts:front:anchorage

Sep 20, 1991

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.

Consequence & remedy

Consequence: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.

Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA99002 · Transfer Cases And Rear Drive Shaft

Opened Jan 7, 1999 · Closed Nov 14, 2000

Status: closed (inferred from source dates) · Power Train

There is no summary currently available

RQ97015 · Parking Pawl

Opened Oct 29, 1997 · Closed Apr 1, 1999

Status: closed (inferred from source dates) · Power Train:automatic Transmission

WHEN THE AUTOMATIC SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARKING PAWL DOES NOT ALWAYS ENGAGE THE PARK GEAR.THIS CAN LEAD TO THE VEHICLE JUMPING OUT OF GEAR UNINTENTIONALLY AND CAUSE THE VEHICLE TO START ROLLING INADVERTENTLY