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1993 Ford Aerostar

Owner reports · Recalls · Investigations

More warning signs than most Aerostar years

Owner complaints for the 1993 Ford Aerostar are substantially higher than the model-year median of 135.5.

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When problems were reported

Mileage at the reported incident

Limited mileage data: 18 of 374 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 99 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 68 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

37 crash reports38 fire reports28 injury reports

Electrical System complaints

99 reports
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Mileage unknown · Sep 29, 1999
Electrical System

SOMETIMES DRIVER CAN'T GET KEY INTO IGNITION. ALSO, AT TIMES, KEY WILL NOT TURN OVER AND COME OUT, AND VEHICLE WILL NOT TURN OFF. DEALER HAS NOT SEEN VEHICLE. *AK

NHTSA ODI #849117

Mileage unknown · Sep 27, 1999
Electrical System

HAD RECEIVED RECALL NOTICE 99V029000 IN THE MAIL. CONTACTED THE DEALER & SET AN APPOINTMENT. AFTER ARRIVING AT DEALER ON APPOINTED DATE, WAS INFORMED NO PARTS WERE AVAILABLE. *AK

NHTSA ODI #848804

Mileage unknown · Aug 5, 1999
Electrical System

HAD RECEIVED RECALL NOTICE CONCERNING IGNITION SWITCH FAILURE SEVERAL MONTHS AGO & CONTACTED DEALER. WAS INFORMED NO PARTS WERE AVAILABLE. PARTS ON BACK ORDER. WOULD NOTIFY WHEN PARTS WERE AVAILABLE. OWNER UPSET. *AK

NHTSA ODI #844463

Mileage unknown · Jul 29, 1999
Electrical System

VEHICLE PARKED IN DRIVEWAY. UPON STARTING MADE STRANGE NOISES AND THEN THERE WAS SMOKE. CONTACTED DEALER AND MANUFACTURER. *AK

NHTSA ODI #843789

Mileage unknown · Jul 27, 1999
Electrical System

HAD RECEIVED RECALL NOTICE #99V02900 & NOTIFIED DEALER. THAT WAS OVER 3 1/2 MONTHS AGO. WAS INFORMED THAT NO PARTS WERE AVAILABLE & WOULD BE CONTACTED WHEN PARTS WERE IN. DEALER WAS ORDERING THE PARTS AT THAT TIME. *AK

NHTSA ODI #843478

Mileage unknown · Jul 20, 1999
Electrical SystemPower Train

VEHICLE EXPERIENCING ELECTRICAL PROBLEMS, PRIOR TO RECALL NOTICE (99V-029). *YC

NHTSA ODI #547374

Mileage unknown · Jul 16, 1999
Electrical SystemFire

WIRING HARNESS UNDER DASH BURNED AND CAUGHT FIRE. NLM

NHTSA ODI #547497

Mileage unknown · Jul 16, 1999
Electrical System

VEHICLE EXPERIENCING ELECTRICAL FAILURE/SHORTS RESULTING IN FAILURE OF SEVERAL COMPONENTS, PRIOR TO RECALL NOTICE (99V-029). *YC

NHTSA ODI #547377

Mileage unknown · Jul 15, 1999
Electrical SystemPower Train

WHILE DRIVING AT 40 MPH THERE WERE NO BRAKE LIGHTS. CONSUMER COULDN'T GET THE VEHICLE OUT OF PARK, AND THE BRAKE FUSE BLEW OUT. DEALER COULDN'T DETERMINE THE CAUSE OF THE PROBLEM. *AK

NHTSA ODI #842428

Mileage unknown · Jul 15, 1999
Electrical System

WHILE DRIVING SOUTHBOUND ON I-65 IN NASHVILLE, MY HUSBAND AND I BEGAN TO SMELL SMOKE AND THEN SUDDENLY SMOKE BEGAN POURING FROM THE STEERING COLUMN OF OUR 1993 FORD AEROSTAR. AFTER PULLING OVER ON THE SIDE OF THE ROAD, I REMOVED OUR TWO SMALL CHILDREN WHILE MY HUSBAND ATTEMPTED TO SHUT OFF THE VAN. ALTHOUGH THE VAN WAS IN PARK…

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WHILE DRIVING SOUTHBOUND ON I-65 IN NASHVILLE, MY HUSBAND AND I BEGAN TO SMELL SMOKE AND THEN SUDDENLY SMOKE BEGAN POURING FROM THE STEERING COLUMN OF OUR 1993 FORD AEROSTAR. AFTER PULLING OVER ON THE SIDE OF THE ROAD, I REMOVED OUR TWO SMALL CHILDREN WHILE MY HUSBAND ATTEMPTED TO SHUT OFF THE VAN. ALTHOUGH THE VAN WAS IN PARK AND THE KEYS HAD BEEN REMOVED, THE VEHICLE STILL WAS ATTEMPTING TO CRANK ITSELF AND WOULD NOT STOP UNTIL WE PLACED THE VAN IN REVERSE (WITH THE PARKING BRAKE ON) AND UNHOOKED THE BATTERY. A MAN WHO STOPPED TO HELP US ALERTED US TO THE FACT THAT THERE HAD BEEN RECALLS ON THE INGNITION SWITCH OF SEVERAL FORD MODELS WHICH COULD POTENTIALLY CAUSE FIRES. THIS IS A VERY DANGEROUS SITUATION AND PEOPLE SHOULD BE ALERTED IN ORDER TO SAVE THEIR LIVES. *AK

NHTSA ODI #708646

Official recalls

2

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

5

PE02076 · 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.

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

EA98016 · Fuel Sender Assembly Fires

Opened Jul 14, 1998 · Closed Feb 12, 1999

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

There is no summary currently available

Additional source detail variants (2)

Vehicle Speed Control:linkages

There is no summary currently available

Vehicle Speed Control:linkages

There is no summary currently available

PE98010 · Fuel Sender Assembly Fires

Opened Feb 13, 1998 · Closed Jul 14, 1998

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

OWNERS ALLEGE THAT FAILURE OF THE FUEL PUMP/SENDER CONNECTOR RESULTS IN SHORT CIRCUIT THAT HAS RESULTED IN VEHICLE FIRES.SYMPTOMS INCLUDE ERRATIC FUEL GAUGE OPERATION, , SMOKE FROM THE DASH ON THE DRIVER'S SIDE NEAR THE STEERING COLUMN (FUEL PUMP FUSIBLE LINK) AND PASSENGER SIDE (FUEL PUMP INERTIA CUTOFF SWITCH), INTERMITTENT STALL AND NO START CONCERNS, AND A BURNING ODOR. SEVERAL INCIDENTS HAVE RESULTED IN DAMAGE TO PLASTIC FUEL TUBES AND/OR FUEL SUPPLY/RETURN TUBES.