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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

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2Investigations

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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

Exterior Lighting complaints

3 reports
Clear category filter
Mileage unknown · Dec 24, 2001
Exterior Lighting

I HAVE BEEN DRIVING AT NIGHT ON SEVERAL DIFFERENT OCCASIONS AND HAD THE HEADLIGHTS SUDDENLY GO OUT ON ME. THE SWITCH FOR THE LIGHTS SEEMS TO BE WARM AT THESE TIMES. THE HEATER SEEMS TO CAUSE THE SWITCH TO HEAT UP AND WHEN IT GETS HOT THE LIGHTS GO OFF. IT MAY CAUSE AN ACCIDENT ONE OF THESE TIMES IF IT ISN'T FIXED. I'M NOT SURE I…

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I HAVE BEEN DRIVING AT NIGHT ON SEVERAL DIFFERENT OCCASIONS AND HAD THE HEADLIGHTS SUDDENLY GO OUT ON ME. THE SWITCH FOR THE LIGHTS SEEMS TO BE WARM AT THESE TIMES. THE HEATER SEEMS TO CAUSE THE SWITCH TO HEAT UP AND WHEN IT GETS HOT THE LIGHTS GO OFF. IT MAY CAUSE AN ACCIDENT ONE OF THESE TIMES IF IT ISN'T FIXED. I'M NOT SURE IF REPLACING THE SWITCH WILL HELP OR IF IT WILL HAPPEN EVEN WITH A NEW SWITCH BEACUSE OF THE HEAT PROBLEM. MAYBE THE DESIGN OF WHERE THE SWITCH IS IS BAD. PLEASE ADVISE ME ON WHAT TO DO. THANK YOU.*AK

NHTSA ODI #755995

Mileage unknown · Apr 16, 2001
Exterior Lighting

MY WIFE HAS TOLD ME THAT ON SEVERAL OCCASIONS SHE HAS REPLACED THE BRAKE LIGHT ON THE RIGHT REAR OF HER 1991 FORD AEROSTAR. I SAW A FORD AEROSTAR MINIVAN WITH A BURNED OUT BRAKE LIGHT ON MY WAY TO WORK TODAY. PLUS SOMEONE TOLD ME ABOUT AN EXACT SAME PROBLEM INVOLVING A FORD AEROSTAR MINIVAN. I HAVE RULED OUT COINCIDENCE. WHAT DO…

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MY WIFE HAS TOLD ME THAT ON SEVERAL OCCASIONS SHE HAS REPLACED THE BRAKE LIGHT ON THE RIGHT REAR OF HER 1991 FORD AEROSTAR. I SAW A FORD AEROSTAR MINIVAN WITH A BURNED OUT BRAKE LIGHT ON MY WAY TO WORK TODAY. PLUS SOMEONE TOLD ME ABOUT AN EXACT SAME PROBLEM INVOLVING A FORD AEROSTAR MINIVAN. I HAVE RULED OUT COINCIDENCE. WHAT DO YOU KNOW ABOUT THIS PROBLEM.? THANKS I ALSO LISTEN TO CARTALK, WITH KLICK AND KLACK, THE TAPPETT BROTHERS. THAT WAS HOW I FOUND OUT ABOUT YOUR HOTLINE.*AK

NHTSA ODI #744130

Mileage unknown · Mar 7, 1996
Exterior Lighting

VEHICLE WITH SEAL BEAM LIGHT KEEPS GOING OUT FOR NO APPARENT REASON. *AK

NHTSA ODI #980378

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