IllustrationDRIVESHAFT WAS TOO HEAVY FOR HIGH SPEED DRIVING , CAUSING VEHICLE VIBRATION. ALSO, RUENING SEALS/TRANSFER CASE,AND CAUSING OTHER DAMAGE . DEALER AND MANUFACTURER HAVE BEEN NOTIFIED. *AK
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 →How this year compares
Owner complaints by model year
Compare all Aerostar years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
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
Power Train complaints
49 reportsCONSUMER DRIVING DOWN ROAD AND WAS GOING FORWARD, AND COULD NOT ENGAGE TO PARK DUE TO TRANSMISSION PROBLEMS. *AK
VEHICLE EXPRIENCE PROBLEM WITH TRANSFER CASE FAILURE WHILE DRIVING ON HIGHWAY AT 80 MPH. CONSUMER LEARN OF A MFR. RECALL ON 1992 VEHICLE CONCERNING TRANSFER CASE/DRIVE SHAFT. SEEKING HELP FROM NHTSA IN THIS MATTER.
THE SNAP RINGS IN THE AUTOMATIC TRANSMISSION BROKE, CAUSING THE PARTS IN THE TRANSMISSION TO BREAK AND MAY CAUSE AN UNEXPECTED LOSS OF VEHICLE CONTROL REPLACED TRANSMISSION TWICE. DEALER CANNOT DETERMINE THE PROBLEM. PLEASE PROVIDE FURTHER INFORMATION. *AK
STRESS FRACTURES IN THE TRANSAXLES.
WHILE DRIVING THE VEHICLE STARTED TO SEVERLY VIBRATE,AND WHEN PULLED OVER THERE WAS OIL ALL OVER. TOWED VEHICLE TO FORD DEALER. DEALER REPAIRED VEHICLE, AND STATED THE TRANSFER CASE WAS DESTROYED AND COULD NOT BE REPLACED. *AK
WHILE DRIVING THE TRANSFER CASE AND TRANSMISSION VIBRATE AND BECOME DETACHED AT HIGHWAY SPEEDS. THE MANUFACTURER HAS BEEN NOTIFIED. *AK
DEFECTIVE DRIVE SHAFT/TRANSFER CASE CAUSED EXCESSIVE VIBRATION TO THE DRIVE LINE. THIS HAS CAUSED DISRUPTION OF SEALS, CRACKING OF CASINGS, SEPARATION OF COMPONENTS, AND LEAKAGE OF TRANSMISSION FLUID ONTO THE EXHAUST SYSTEM. THE FAILURES ARE FIRST NOTICED BY SMOKE ESCAPING FROMUNDERNEATH THE VEHICLE AND SUDDEN LOSS OF TRANSMIS…
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DEFECTIVE DRIVE SHAFT/TRANSFER CASE CAUSED EXCESSIVE VIBRATION TO THE DRIVE LINE. THIS HAS CAUSED DISRUPTION OF SEALS, CRACKING OF CASINGS, SEPARATION OF COMPONENTS, AND LEAKAGE OF TRANSMISSION FLUID ONTO THE EXHAUST SYSTEM. THE FAILURES ARE FIRST NOTICED BY SMOKE ESCAPING FROMUNDERNEATH THE VEHICLE AND SUDDEN LOSS OF TRANSMISSION FUNCTION.
THE NEUTRAL SAFETY KIT MALFUNCTIONED, CAUSING THE KEYS TO BE REMOVED AT ANY NEUTRAL/ DRIVE ETC. POSITION WHICH CAUSED A ROLLOVER AND ACCIDENT. PLEASE PROVIDE DETAILS. *AK
WHILE DRIVING THE DRIVESHAFT BROKE, CAUSE UNKNOWN. PLEASE GIVE ANY FURTHER DETAILS. *AK
Official recalls
396V071000 · 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
2EA99002 · 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