IllustrationFORD CLAIM VIN NUMBER IS NO UNDER RECALL NUMBER 97V204000. TRANSFER CASE ARE EXACTLY LIKE THE OTHERS THEY HAVE REPAIRED UNDER RECALL. VAN MANUF. DATE IS 11/3/91 AND RECALL MANUF. DAT IS 1/2/92
1992 Ford Aerostar
Owner reports · Recalls · Investigations
More warning signs than most Aerostar years
Owner complaints for the 1992 Ford Aerostar are substantially higher than 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: 12 of 317 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.
- Power Train. Review the 75 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 64 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 52 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
29 crash reports30 fire reports19 injury reports
Power Train complaints
75 reportsWHILE DRIVING THE VAN ABOUT 60 MPH THE TRANSFER CASE WENT OUT. VAN WAS TOWED TO THE DEALERSHIP. DEALER TOLD CONSUMER THAT THERE WAS A RECALL ON THE TRANSFER CASE, AND HIS VEHICLE SHOULD HAVE BEEN INCLUDED. RECALL # 97V20400 FORD/TRANSFER CASE/DRIVESHAFT. *AK
WHILE DRIVING NOTICED VIBRATION COMING FROM VEHICLE; REPAIRMAN INFORMED CONSUMER THAT TRANSFER CASE WENT OUT, AND WAS TOLD OF A RECALL ON TRANSFER CASE. CALLED MANUFACTURER AND WAS INFORMED THAT VEHICLE WAS NOT ON THE RECALL LIST. VEHICLE EXPERIENCING SAME PROBLEM AS RECALL #97V- 204. *AK
CONSUMER EXPERIENCED PROBLEM WITH TRANSFER CASE FAILURE. WHILE DRIVING ON THE HIGHWAY DURING APPROXIMATELY 75 MPH, WITH THREE CHILDREN IN THE BACK SEAT, TRANSFER CASE BROKE IN THREE PIECES, CAUSING THE TRANMISSION/DRIVESHAFT & MUFFLER TO DROP AND PUNCTURE A HOLE IN GAS TANK . DEALER NOTIFIED AND REFUSED TO REPAIR UNLESS COST G…
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CONSUMER EXPERIENCED PROBLEM WITH TRANSFER CASE FAILURE. WHILE DRIVING ON THE HIGHWAY DURING APPROXIMATELY 75 MPH, WITH THREE CHILDREN IN THE BACK SEAT, TRANSFER CASE BROKE IN THREE PIECES, CAUSING THE TRANMISSION/DRIVESHAFT & MUFFLER TO DROP AND PUNCTURE A HOLE IN GAS TANK . DEALER NOTIFIED AND REFUSED TO REPAIR UNLESS COST GOES TO THE CONSUMER. *AK
WHEN TRYING TO CUT THE VEHICLE OFF THE KEY WILL NOT TURN BACK TO THE LOCK POSITION. THE VEHICLE HAD TO BE TOWED. THE TRANSMISSION MODULES AND THE WIRING HARNESS WERE BURNT. CONSUMER WAS TOLD THAT THEY VEHICLE WAS NOT PART OF THE RECALL #97V204000. *AK
WHILE DRIVING BACK FROM SKIING CONSUMER'S AUTO COMPLETELY STOPPED DRIVING/MOVING. *AK
TRANSMISSION MALFUNCTIONED. THERE WERE STRANGE CLUNKS/BURNED FLUID AND BALKY IN REVERSE ENGAGEMENT. *MJS
LEAKS IN ENGINE, TRANSFER CASE, AND AUTOMATIC TRANSMISSION CAUSED DRIVETRAIN TO VIBRATE. ADDITIONALLY, VEHICLE'S BRAKES ARE DANGEROUSLY INADEQUATE. BOTH FRONT DISCS AND DRUMS ARE UNDERSIZED FOR VEHICLE, RESULTING IN LONG STOPPING DISTANCES AND EXCESSIVE DISC WARPING AND WEARING. THE REAR ANTI LOCK BRAKES ARE TOTALLY NONFUNCT…
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LEAKS IN ENGINE, TRANSFER CASE, AND AUTOMATIC TRANSMISSION CAUSED DRIVETRAIN TO VIBRATE. ADDITIONALLY, VEHICLE'S BRAKES ARE DANGEROUSLY INADEQUATE. BOTH FRONT DISCS AND DRUMS ARE UNDERSIZED FOR VEHICLE, RESULTING IN LONG STOPPING DISTANCES AND EXCESSIVE DISC WARPING AND WEARING. THE REAR ANTI LOCK BRAKES ARE TOTALLY NONFUNCTIONAL.
DRIVE TRAIN PROBLEMS. DEALER REBUILD THE REAR END TWICE, REPLACE/REBUILD THE TRANSFER CASE TWICE AND REPAIRED IT SEVERAL TIMES. THIS IS THE SECOND TRANSMISSION. THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR. SECOND REPAIR/REPLACE THE TRA…
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DRIVE TRAIN PROBLEMS. DEALER REBUILD THE REAR END TWICE, REPLACE/REBUILD THE TRANSFER CASE TWICE AND REPAIRED IT SEVERAL TIMES. THIS IS THE SECOND TRANSMISSION. THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR. SECOND REPAIR/REPLACE THE TRANSFER CASE AFTER ITS SECOND CATASTROPIC FAILURE AT HIGHWAY SPEED.
TRANSFER CASE FAILED/LEAKED PRIOR TO RECALL, RECALL REPAIRS REFUSED TO TO DATE OF MAKE/MODEL (97V-204).
Official recalls
399V094000 · Power Train:transfer Case (4-WHEEL Drive)
Apr 28, 1999
VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). 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.
Consequence & remedy
Consequence: 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.
99V029000 · Electrical System:ignition:switch
Feb 9, 1999
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.
Consequence & remedy
Consequence: 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.
97V204000 · Power Train:transfer Case (4-WHEEL Drive)
Nov 13, 1997
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.
Consequence & remedy
Consequence: 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.
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
5PE02076 · Luggage Compartment Door Drops Abruptly
Opened Oct 10, 2002 · Closed Mar 10, 2003
Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate:support Device/strut
ODI HAS IDENTIFIED 30 INCIDENTS RESULTING IN MINOR TO MODERATE PERSONAL INJURIES THAT HAVE BEEN CAUSED BY ABRUPT DOOR DROPS OVER THE APPROXIMATELY EIGHT - TWELVE YEAR PERIOD OF PRODUCT USAGE AND EXPOSURE (1991-1995 TO 2003).MOST OF THE INJURY INCIDENTS APPEAR TO HAVE BEEN CAUSED BY A FRACTURE OF THE GAS FILLED LIFT ASSIST CYLINDER MOUNTING STUD.STUD FRACTURES HAVE OCCURRED RANDOMLY OVER TIME AND DO NOT EXHIBIT ANY APPARENT TREND RELATING TO DATE OF VEHICLE PRODUCTION OR TIME-IN-SERVICE (EXPOSURE).THE ODI CLOSING REPORT SUMMARIZES THE DETAILS OF THIS INVESTIGATION.
PE99035 · Front Brake Hose
Opened May 12, 1999 · Closed Sep 23, 1999
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
ALLEGED THAT A FRONT BRAKE HOSE RUPTURES OR FAILS AT THE INTERFACE BETWEEN THE RUBBER HOSE AND THE BRASS FITTING
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
RQ98012 · Transfer Cases And Rear Driveshaft
Opened Jul 31, 1998 · Closed Jan 7, 1999
Status: closed (inferred from source dates) · Power Train:transfer Case (4-WHEEL Drive)
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