IllustrationREAR SEAL ON THE TRANSFER CASE BECAME LOOSE, CAUSING FAILURE OF COMPONENTS WITHIN THE TRANSFER CASE.
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 reportsDRIVER'S POWER WINDOW MALFUNCTIONED. IN ADDITION, TRANSMISSION FAILED/ABS LIGHT INTERMITTENTLY COMES ON/MASTER CYLINDER FAILED, CAUSING AN ACCIDENT/AIR CONDITIONING COMPRESSOR FAILED/TIE RODS REPLACED/TAIL LIGHTS REPEATED LY REPLACED/IGNITION SWITCH FAILED, CAUSING A FIRE/REPEATED ENGINE OIL LEAKS AND CATALYTIC CONVERTER REPLACE…
Read full complaint
DRIVER'S POWER WINDOW MALFUNCTIONED. IN ADDITION, TRANSMISSION FAILED/ABS LIGHT INTERMITTENTLY COMES ON/MASTER CYLINDER FAILED, CAUSING AN ACCIDENT/AIR CONDITIONING COMPRESSOR FAILED/TIE RODS REPLACED/TAIL LIGHTS REPEATED LY REPLACED/IGNITION SWITCH FAILED, CAUSING A FIRE/REPEATED ENGINE OIL LEAKS AND CATALYTIC CONVERTER REPLACED.
(RECALL NO. 97V204000); AFTER THE RECALL HAD BEEN PERFORMED THE TRANSFER CASE STARTED TO LEAK 6 DAYS LATER. BEFORE THE RECALL WORK WAS DONE THERE WASN'T A LEAK. *AK
TRANSMISSION TRANSFER CASE FAILED, CAUSING FLUID TO FOAM AND OVERFLOW.
TRANSFER CASE LEAKS OIL, CAUSING DRIVE SHAFT TO SEPERATE AND U-JOINT TO FAIL.
VEHICLE OUT OF SCOPE OF RECALL CAMPAIGN. TRANSFER CASE SEAL FAILURE.
TRANSFER CASE SEAL FAILURE.
TRANSMISSION LOST ALL POWER WHILE VEHICLE IN MOTION, PARTICULARLY IN THE PASSING GEAR.
TRANSFER CASE FAILURE.
TRANSMISSION FAILURE.
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