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
What owners actually said
223 reports
Mileage unknown · Apr 27, 2000
Power Train
VIBRATION PROBLEMS HAVE BEEN CONSISTENT SINCE DATE OF PURCHASE. OTHER OWNERS REPORTED VIBRATION PROBLEMS AND DRIVELINES WERE NOTED AS DEFECTIVE. NONE OF THE CORRECTIONS BY FORD SERVICE CORRECTED THE PROBLEMS IN MY AEROSTAR. RECENT VISITS TO FORD RESULTED IN A SELF DIAGNOSED TRANSFER CASE OUTPUT SHAFT PLAY, CONFIRMED BY MECHAN…
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VIBRATION PROBLEMS HAVE BEEN CONSISTENT SINCE DATE OF PURCHASE. OTHER OWNERS REPORTED VIBRATION PROBLEMS AND DRIVELINES WERE NOTED AS DEFECTIVE. NONE OF THE CORRECTIONS BY FORD SERVICE CORRECTED THE PROBLEMS IN MY AEROSTAR. RECENT VISITS TO FORD RESULTED IN A SELF DIAGNOSED TRANSFER CASE OUTPUT SHAFT PLAY, CONFIRMED BY MECHANICS AS POSSIBLE CAUSE FOR INCREASINGLY NOTICABLE DRIVE TRAIN VIBRATIONS. CHECK BY SERVICE REPRESENTATIVE REVEALED SAFETY RECALLS (97S83 & 99S13) FOR 1992-1997 FOR AWD AEROSTARS. THE DEALER, FORD AREA REP AND FORD CUSTOMER SERVICE REFUSE TO PERFORM RECOMMENDED SERVICE ACTION FOR MY AEROSTAR AT THEIR EXPENSE CLAIMING THAT THE RECALLS WERE BY VIN # AND MY VEHICLE WAS NOT INCLUDED. FORD HAS ISSUED OVER 170 RECALLS AND SERVICE BULLETINS ON MY VEHICLE BUT ONLY ONE WAS SENT TO ME AND I HAD THE WORK DONE. FORD SHOULD INCLUDE MY VEHICLE IN THE RECALL AND REPLACE ALL DRIVELINE PARTS THAT HAVE BEEN DAMAGED DUE TO THEIR FAILURE TO CORRECTLY PERFORM RECALLED REPAIRS. *AK
NHTSA ODI #722007
Mileage unknown · Mar 29, 2000
Vehicle Speed Control
CAR ACCELERATES UNCONTROLLABLY, LOUD TICKING NOISE. VEHICLE WOULD NOT TURN OFF, EVEN WITH KEYS OUT OF THE IGNITION. VEHICLE TOWED TO DEALER, THEY COULD NOT FIND PROBLEM. *AK *ML
NHTSA ODI #859395
Mileage unknown · Mar 29, 2000
Vehicle Speed ControlCrash
WHEN HUSBAND STARTED VEHICLE IT SUDDENLY ACCELERATED WITHOUT PRIOR WARNING, COLLISION RESULTED. DEALER REPAIRED VEHICLE BUT COULD NOT FIND THE SOURCE OF THE PROBLEM. *AK *ML
NHTSA ODI #859394
Mileage unknown · Mar 28, 2000
Service Brakes, HydraulicCrash
WHILE GOING IN REVERSE, APPLIED THE BRAKES, BUT BRAKES FAILED AND THE PEDAL WENT DOWN TO THE FLOORBOARD RESULTING IN A MINOR CRASH. UPON INSPECTION, BRAKE FLUID WAS LEAKING UNDER THE RIGHT FRONT OF THE VAN, THE BRAKE HOSE WAS DANGLING COMPLETELY FREE OF THE VEHICLE. THE HOSE HAD SEPARATED FROM THE VEHICLE AT THE SMALL BRACKET…
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WHILE GOING IN REVERSE, APPLIED THE BRAKES, BUT BRAKES FAILED AND THE PEDAL WENT DOWN TO THE FLOORBOARD RESULTING IN A MINOR CRASH. UPON INSPECTION, BRAKE FLUID WAS LEAKING UNDER THE RIGHT FRONT OF THE VAN, THE BRAKE HOSE WAS DANGLING COMPLETELY FREE OF THE VEHICLE. THE HOSE HAD SEPARATED FROM THE VEHICLE AT THE SMALL BRACKET ATTACHED TO THE BODY OF THE VAN. IT IS POSSIBLE THAT THE TUBE-LIKE CONNECTION BETWEEN THE HOSE AND BODY WAS TOO LIGHT-WEIGHT TO TAKE THE CONSTANT STEERING AND VERTICAL STRAINS. *AK *ML
NHTSA ODI #859347
Mileage unknown · Mar 6, 2000
Service Brakes, Hydraulic
REPLACED ORGINAL MASTER CYLINDER WITH REBUILT FORD MASTER CYLINDER AT APPROX. 100,000 MILES, 8/9/97. REPLACED REBUILT MASTER CYLINDER WITH ANOTHER FORD REBUILT MASTER CYLINDER 3/15/1999. REPLACED BRAKE COMPUTER AND DUMP VALVE JULY-AUG. 1999. REPLACED MASTER CYLINDER WITH YET ANOTHER FORD REBUILT MASTER CYLINDER (UNDER WARRANT…
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REPLACED ORGINAL MASTER CYLINDER WITH REBUILT FORD MASTER CYLINDER AT APPROX. 100,000 MILES, 8/9/97. REPLACED REBUILT MASTER CYLINDER WITH ANOTHER FORD REBUILT MASTER CYLINDER 3/15/1999. REPLACED BRAKE COMPUTER AND DUMP VALVE JULY-AUG. 1999. REPLACED MASTER CYLINDER WITH YET ANOTHER FORD REBUILT MASTER CYLINDER (UNDER WARRANTY)...FAILED ON FEB. 27, 2000. AUTO MECHANIC PULLS NEWLY REBUILT MASTER CYLINDERS FROM BOXES AND THEY DO NOT WORK. CURRENTLY, AM AWAITING ARRIVAL OF NEW FORD MASTER CYLINDER, IN ATTEMPT TO CORRECT PROBLEM. SINCE THESE PARTS WERE UNDER WARRANTY BY FORD, I FEEL THEY SHOULD COMPENSATE MECHANIC FOR WASTED TIME OF REPLACING CONSTANTLY DEFECTIVE PARTS. MECHANIC HAS WORKED WITH FORD REP IN ATTEMPT TO RESOLVE PROBLEMS. AS OF TODAY, VAN HAS BEEN IN SHOP FOR 4 WEEKS (EXCLUDING WEEKEND WHEN IT FAILED AGAIN). MAIN FAMILY TRANSPORTATION TO A FAMILY OF 7. *AK
NHTSA ODI #719770
Mileage unknown · Nov 15, 1999
Vehicle Speed Control
VEHICLE EXPERIENCED SUDDEN ACCELERATION RESULTING IN VEHICLE BEING OUT OF CONTROL (ATTORNEY FOR CONSUMER). MJS
NHTSA ODI #549541
Mileage unknown · Nov 4, 1999
Power Train
THE FRONT SEAL FROM THE TRANSMISSION HAD STARTED LEAKING DOWN ON THE EXHAUST CAUSING ENGINE TO CATCH FIRE. *YC
NHTSA ODI #852543
Mileage unknown · Oct 25, 1999
Latches/locks/linkages
WHEN THE SLIDING DOOR ON THE RIGHT HAND HAD BEEN OPENED & THEN CLOSED, IT COULD BE REOPENED AGAIN FROM EITHER INSIDE OR OUTSIDE. COULD HEAR THE CLICKING SOUND, BUT THE DOOR IS NOT OPENING. ALL THE LOCKS WORK JUST FINE. TAKING VEHICLE TO MECHANIC TO CHECK & HAVE IT REPAIRED. *AK
NHTSA ODI #851564
Mileage unknown · Aug 5, 1999
Electrical SystemFire
NO SUMMARY
NHTSA ODI #709626
Mileage unknown · Jul 21, 1999
Electrical SystemFire
WHILE DRIVING AT 30 MPH SMELLED SOME SMOKE, AND PULLED OVER, LIFTED THE HOOD AND THERE WAS A FIRE WITHIN THE ALTERNATOR AND HARNESS. CONSUMER AND SOMEONE ELSE USED PUT THE FIRE OUT. *AK
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.
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
1991 Ford Aerostar Problems, Complaints & Recalls | Skip That Year
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