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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.

About this comparison →

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
150,000 miles · Feb 11, 2004
Electrical System

HEADLIGHT SWITCH RUNS SO HOT IT MELTS THE PLASTIC PLUG BODY INTO WHICH THE WIRING HARNESS TERMINALS ARE INSERTED. I WILL BE PURCHASING THE SECOND REPLACEMENT SWITCH TODAY (3 TOTAL SWITCHES SINCE NEW). WITH THE INSTRUMENT PANEL TRIM REMOVED AND 1/2 HR DRIVING WITH HEADLIGHTS ON THE SWITCH IS TOO HOT TO TOUCH. THE CONTACT THAT …

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HEADLIGHT SWITCH RUNS SO HOT IT MELTS THE PLASTIC PLUG BODY INTO WHICH THE WIRING HARNESS TERMINALS ARE INSERTED. I WILL BE PURCHASING THE SECOND REPLACEMENT SWITCH TODAY (3 TOTAL SWITCHES SINCE NEW). WITH THE INSTRUMENT PANEL TRIM REMOVED AND 1/2 HR DRIVING WITH HEADLIGHTS ON THE SWITCH IS TOO HOT TO TOUCH. THE CONTACT THAT PROVIDES POWER TO THE TAIL LIGHTS, INSTRUMENT PANEL LIGHTS AND RADIO NIGHT LIGHT SEEMS TO BE THE SOURCE OF HEAT AS THAT TERMINAL SHOWS THE GREATEST DAMAGE DUE TO HEATING.*AK

NHTSA ODI #10056983

Mileage unknown · Jan 15, 2004
Unknown Or Other

THE SWITCH DOES NOT WORK PROPERLY. WHEN YOU TAKE THE KEY OUT SWITCH IS STILL ON. HAS TO BE JIGGLED ABOUT TO BE SURE IT IS TURNED OFF. HAS BEEN ON AND LIGHTS INSIDE HAVE RUN BATTERY DOWN. ALSO WHEN DRIVING THE DOOR AJAR LIGHT STAYS ON OR THE CHECK OIL LIGHT STAYS ON AND YOU CAN HEAR NOISES IN DASH. THEY SOUND LIKE CLICKING NOI…

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THE SWITCH DOES NOT WORK PROPERLY. WHEN YOU TAKE THE KEY OUT SWITCH IS STILL ON. HAS TO BE JIGGLED ABOUT TO BE SURE IT IS TURNED OFF. HAS BEEN ON AND LIGHTS INSIDE HAVE RUN BATTERY DOWN. ALSO WHEN DRIVING THE DOOR AJAR LIGHT STAYS ON OR THE CHECK OIL LIGHT STAYS ON AND YOU CAN HEAR NOISES IN DASH. THEY SOUND LIKE CLICKING NOISES. WANT TO FIND OUT IF THERE ARE ANY RECALLS ON MY VAN. I PURCASED IT USED AND LOVE IT EXCEPT FOR THIS PROBLEM. THANK YOU NOVEEN MCGEE

NHTSA ODI #10069342

Mileage unknown · Nov 19, 2003
Power TrainService Brakes, Hydraulic

WHILE DRIVING VEHICLE LOST CONTROL. TOOK VEHICLE TO INDEPENDENT REPAIR SHOP, AND MECHANIC INDICATED THAT THIS VEHICLE WAS ON RECALL CONCERNING TRANSFER CASE PROBLEM. ALSO, HAD BRAKE SYSTEM PROBLEM. *AK

NHTSA ODI #10048270

128,850 miles · Nov 5, 2003
Tires

WHILE DRIVING AT 35 MPH REAR TIRE TREAD SEPARATED. TIRE MODEL UNKNOWN, SIZE P215/70R14, DOT# DVHYFRKR4201 .

NHTSA ODI #10046390

Mileage unknown · Oct 16, 2003
Tires

DEAR NHTSA; BELOW IS CORRESPONDENCE WITH GOODYEAR TIRE COMPANY. I HAVE HAD PROBLEMS WITH THE DUNLOP ROVER TOURING GT TIRE NUMBER PN P22570514 AS DETALED BELOW. I DO NOT HAVE FURTHER TIRE INFORMATION SINCE THE VEHICLE IS IN THE UNITED STATES BUT I CAN OBTAIN IT AS NECESSARY. THANK YOU, MARK DEVRIES *LA 3 OCTOBER 2003 …

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DEAR NHTSA; BELOW IS CORRESPONDENCE WITH GOODYEAR TIRE COMPANY. I HAVE HAD PROBLEMS WITH THE DUNLOP ROVER TOURING GT TIRE NUMBER PN P22570514 AS DETALED BELOW. I DO NOT HAVE FURTHER TIRE INFORMATION SINCE THE VEHICLE IS IN THE UNITED STATES BUT I CAN OBTAIN IT AS NECESSARY. THANK YOU, MARK DEVRIES *LA 3 OCTOBER 2003 DEAR SIR: ON 6-22-01 I PURCHASED 4 DUNLOP ROVER TOURING LT TIRES FOR MY 1992 AEROSTAR VAN, MILAGE 108,098 AT SEARS EAGLE RIDGE MALL, LAKE WALES FL. ON 8-6-03, THE VEHICLE (138,690 MILES) WAS RETURNED TO SEARS EAGLE RIDGE BECAUSE THE RIGHT FRONT TIRE WAS SEPARATING FROM THE TREAD. A NEW DUNLOP ROVER TOURING LT WAS MOUNTED. ON 8-12-03 MY FAMILY WERE ON THE FLORIDA TURNPIKE WHEN THEY SUDDENLY HEARD A "THUMP,THUMP" FROM THE RIGHT REAR SIMILAR TO THE SOUND HEARD THE PREVIOUS WEEK WITH THE SEPARATED TIRE. THIS TIME THE TIRE EXPLODED AND MY WIFE BARELY MANAGED TO CONTROL THE VEHILE WHILE STEERING THE VAN TO THE SIDE OF THE TURNPIKE. I HAVE DIGITAL PICTURES OF THE EXPLODED TIRE AND MY VAN. MY FAMILY CONTINUED TO LOUISIANA WHERE THEY DEPARTED FOR INDONESIA WHERE WE ARE RESIDENT WITH CHEVRONTEXACO, LEAVING THE VAN WITH MY DAUGHTER WHO ATTENDS UNIVERSITY IN LAFAYETTE, LA. I THINK THE ORIGINAL DUMLOP TIRES ARE DEFECTIVE AND ARE UNSAFE. HOW ELSE DO YOU EXPLAIN ONE BLOWOUT AND ONE POTENTIAL BLOWOUT WITHIN 300 MILES. I HAVE INSTRUCTED MY DAUGHTER TO ONLY USE THE VAN WITHIN TOWN AND NOT TO USE IT ON THE HIGHWAY OR EXCEED 50 MPH. I DO NOT FEEL THE REMAINING TIRES ARE SAFE AND AM VERY CONCERNED THAT THEY ALSO MAY SUDDENLY FAIL. THE NUMBER GIVEN ABOVE IS FOR MY PARENTS HOME. I CAN EMAIL WITH PICTURES OF THE EXPLODED TIRE AND SCANNED COPY OF THE EXPLODED TIRE REPLACEMENT PURCHASE. I AM ALSO MAILING A COPY OF THIS EMAIL AND SUPPORTING DOCUMENTS TO GOODYEAR CORPORATE HEADQUARTERS. I INTENDED TO TAKE CARE OF THIS SOONER BUT DID NOT RECEIVE COPIES OF THE EXPLODED TIRE UNTIL RECENTLY. THANK YOU, MARK DEVRIES MDVRIES@PTCPI.COM 3 OCTOBER *LA

NHTSA ODI #10043007

120,000 miles · Oct 14, 2003
Air BagsSeat BeltsCrashInjury

THE VEHICLE WENT OVER A PUDDLE OF WATER AND LOST CONTROL.. DRIVER'S SIDE SEAT BELT UNFASTENED AT THAT POINT. VEHICLE THEN ROLLED OVER FOUR TIMES. UPON IMPACT, AIR BAGS DID NOT DEPLOY. DRIVER WAS EJECTED THROUGH THE WINDSHIELD, AND SUSTAINED A BROKEN COLLAR BONE AND THREE BROKEN RIBS. ALSO PASSENGER IN THE FRONT SEAT SUSTAI…

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THE VEHICLE WENT OVER A PUDDLE OF WATER AND LOST CONTROL.. DRIVER'S SIDE SEAT BELT UNFASTENED AT THAT POINT. VEHICLE THEN ROLLED OVER FOUR TIMES. UPON IMPACT, AIR BAGS DID NOT DEPLOY. DRIVER WAS EJECTED THROUGH THE WINDSHIELD, AND SUSTAINED A BROKEN COLLAR BONE AND THREE BROKEN RIBS. ALSO PASSENGER IN THE FRONT SEAT SUSTAINED INTERNAL HEAD AND BACK INJURIES. *AK

NHTSA ODI #10042868

Mileage unknown · Oct 7, 2003
Electrical System

HEADLIGHTS START TO GO OFF AND ON AFTER 10 MINS OF DRIVING. VERY DANGEROUS, DASH LIGHTS GO OUT TOO. FORD SAYS THE SWITCH NEEDS TO BE REPLACED, MY HUSBAND TOOK THE SWITCH OUT AND ITS GETS WAY TOO HOT AND CAUSES THE LIGHTS TO GO OFF. *JB

NHTSA ODI #10041400

108,500 miles · Aug 21, 2003
Service Brakes, Hydraulic

CANCELLATION OF GENERAL RECALL TSB94B38 WHICH HAD TO DO WITH ABS GENERAL RECALL WHICH FORD SAYS IS NOW EXPIRED. MY REAR BRAKES LOCKUP FIRST THING IN THE MORNING, AND SOMETIMES DURING THE DAY, SOMETIMES I GET A ABS LIGHT.*AK

NHTSA ODI #10033247

Mileage unknown · Aug 5, 2003
Power Train

CONSUMER STATES THAT WHILE DRIVING AT ANY SPEED AND WITH NO WARNING TRANSMISSION WILL LOCK UP. DEALER NOTIFIED.*AK

NHTSA ODI #10032088

Mileage unknown · Aug 5, 2003
Engine And Engine Cooling

CONSUMER STATES THAT WHILE DRIVING AT ANY SPEED AND WITH NO WARNING VEHICLE WILL SHUT OFF, CAUSING CONSUMER TO PULL OVER, AND IT WILL BE HARD TO GET THE VEHICLE BACK STARTED.DEALER NOTIFIED.*AK

NHTSA ODI #10032085

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.