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: 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
What owners actually said
374 reports
Mileage unknown · May 9, 2000
Electrical SystemEngine And Engine CoolingEquipment
I WIIL BE FAXING OVER THE INFORMATION REGARDING THIS 93 FORD AEROSTAR. NO SAFETY DEFECT LISTED IN THE SUMMARY. *AK THE VEHICLE HAD STARTING PROBLEMS. THE TRANSMISSION FAILED. THE A/C FAILED. RELAY STARTER MOTOR FAILED. THE HEATER CORE FAILED. POWER STEERING WAS INOPERATIVE. TIE RODS ON BOTH TIRES FAILED. WATER PUMP FAILED…
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I WIIL BE FAXING OVER THE INFORMATION REGARDING THIS 93 FORD AEROSTAR. NO SAFETY DEFECT LISTED IN THE SUMMARY. *AK THE VEHICLE HAD STARTING PROBLEMS. THE TRANSMISSION FAILED. THE A/C FAILED. RELAY STARTER MOTOR FAILED. THE HEATER CORE FAILED. POWER STEERING WAS INOPERATIVE. TIE RODS ON BOTH TIRES FAILED. WATER PUMP FAILED. *YH
NHTSA ODI #722457
Mileage unknown · Apr 27, 2000
Latches/locks/linkages
WHILE DRIVING ON THE HIGHWAY SLIDING DOOR ON THE PASSENGER'S SIDE CAME OPEN. THE DOOR IS CLOSED, BUT OWNER IS NOT SURE IF THE DOOR WILL OPEN AGAIN OR NOT. THE DEALER IS NOT AWARE OF THE PROBLEM. *AK
NHTSA ODI #861035
Mileage unknown · Apr 17, 2000
Power Train
I WENT TO PUT THE VEHICLE IN GEAR AND THE LINKAGE SNAPPED. WHEN I CONTACTED THE FORD DEALER IN HAYS KANSAS THEY TOLD ME THIS WAS A COMMON PROBLEM. *AK
NHTSA ODI #721565
Mileage unknown · Apr 14, 2000
Electrical System
RECALL 99V029/IGNITION SWITCH. DEALER HAS ATTEMPTED TO REPAIR VEHICLE UNDER RECALL ON SEVERAL OCCASIONS; HOWEVER, THE CONDITION OF THE VEHICLE WORSENED. *AK
NHTSA ODI #860344
Mileage unknown · Apr 6, 2000
Exterior Lighting
THE BRAKES LIGHTS STARTED W/ FLICKERING ON/OFF WHEN BRAKING. AFTER MONTHS OF THIS, BRAKES LIGHT DOES NOT WORK AT ALL. WE HAVE REPLACED FUSES AND BULBS AND THEY CONTINUE TO BURN OUT WITHIN DAYS.
NHTSA ODI #721107
Mileage unknown · Mar 14, 2000
Electrical SystemFire
ALTERNATOR PUTS OUT TOO MUCH JUICE THEN ITS NEEDS AFTER A CERTAIN AMOUNT OF MILEAGE. ALTERNATOR HAS BEEN REPLACED 4 TIMES. WOULD SMELL SOMETHING BURNING. POPPED HOOD & FOUND FLAMES JUMPING FROM ENGINE. VEHICLE THEN DIED OUT. VEHICLE TOWED TO MECHANIC & WAS INFORMED THAT PROBLEM WOULD CAUSE VEHICLE TO CATCH FIRE.*AK
NHTSA ODI #858534
Mileage unknown · Mar 13, 2000
Electrical System
AFTER RECALL REPAIR OF THE IGNITION SWITCH (99V-029) THE HORN NO LONGER FUNCTIONED, THE AIRBAG INDICATOR FLASHES AFTER THE IGNITION IS SWITCHED ON, ALARM SOUNDS WHEN THE IGNITION IS SWITCHED OFF AND THE CRUISE CONTROL IS INOPERATIVE. NLM
NHTSA ODI #551317
Mileage unknown · Feb 25, 2000
Air BagsSeat Belts
FRONT SEATBELT MALFUNCTIONED, CAUSING THE SEATBELT NOT TO RETRACT, WHICH WON'T PROTECT THE OCCUPANT IN EVENT OF A CRASH. ALSO, AIRBAG LIGHT CAME ON, INDICATING A PROBLEM WITH THE AIR BAG SYSTEM. FORD/DEALER HAVE REFUSED TO COVER THE REPAIR OF EITHER MECHANISM. *AK *ML
NHTSA ODI #857561
Mileage unknown · Feb 23, 2000
Power Train
THIS PROBLEM WAS SUPPOSEDLY FIXED IN NOV. 1998 BY FAMILY FORD MERCURY IN CARLISLE, PA IN ACCORDANCE WITH MFG. RECALL 97S83. HOWEVER, THE RECALL SPECIFIES THE REPLACEMENT OF THE ORIGINAL STEEL DRIVE SHAFT WITH AN ALUMINUM DRIVE SHAFT. DURING THE REPAIR OF THE VEHICLE IT WAS QUITE APPARENT THAT THE VEHICLE DID NOT HAVE AN ALUMINUM…
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THIS PROBLEM WAS SUPPOSEDLY FIXED IN NOV. 1998 BY FAMILY FORD MERCURY IN CARLISLE, PA IN ACCORDANCE WITH MFG. RECALL 97S83. HOWEVER, THE RECALL SPECIFIES THE REPLACEMENT OF THE ORIGINAL STEEL DRIVE SHAFT WITH AN ALUMINUM DRIVE SHAFT. DURING THE REPAIR OF THE VEHICLE IT WAS QUITE APPARENT THAT THE VEHICLE DID NOT HAVE AN ALUMINUM DRIVE SHAFT INSTALLED. APPARENTLY THE RECALL WAS EITHER NOT PERFORMED OR NOT PERFORMED CORRECTLY CAUSING A POTENTIALLY DANGEROUS FAILURE. I HAVE ASKED FORD TO REISSUE THE RECALL ON THIS VEHICLE AND THEY HAVE DECLINED.*AK
NHTSA ODI #719155
Mileage unknown · Feb 15, 2000
Electrical System
DEALER WAS NOT ABLE TO FIX THE RECALL ON IGNITION SWITCH. THE DEFECTIVE PART WAS CHANGED, BUT THE PROBLEM HAS REOCCURRED. DEALER HAS BEEN CONTACTED A SECOND TIME. *AK
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.
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.
1993 Ford Aerostar Problems, Complaints & Recalls | Skip That Year
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