IllustrationTHE WIRING HARNESS IN MY STEERING COLUME IS DEFECTIVE. THIS WILL BE THE SECOND TIME IN 6 YRS THAT THIS HAS HAD TO BE REPLACED. THE HARNESS CONTROLLS THE AIRBAGE, HORN AND CRUISE CONTROLL. ALSO THE IGITION SWITCH IS FAULTY, THE KEY CAN BE REMOVED WHILE THE VEHICLE IS RUNNING
1994 Ford Aerostar
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 1994 Ford Aerostar do not stand out strongly from 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: 15 of 257 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 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 44 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 42 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
22 crash reports27 fire reports23 injury reports
Electrical System complaints
69 reportsCONSUMER STATES THAT A FIRE STARTED UNDER THE DASH WHILE DRIVING. LOCAL FIRE DEPARTMENT ARRIVED TO EXTINGUISH THE FIRE. NLM
CONSUMER SAW SMOKE COMING FROM STEERING COLUMN, THEN HEARD A POP WITH A CLOUD. CONSUMER HAD NO LIGHTS, AND STATED THAT SMOKE WAS COMING FROM STEERING COLUMN AND FILLED THE CAR. VEHICLE WAS TOWED TO DEALER, AND THEY STATED A GROUND WIRE BURNED, AND CAUSED THE SMOKE.*AK *YH
THE VEHICLE JUST WENT UP IN FLAMES. *AK
AIR BAG LIGHT ON THE INSTRUMENT PANEL WILL ILLUMINATE ERRATICALLY, THEN GO OFF WHILE OPERATING VEHICLE AT ANY SPEED. ALSO, HAS EXPERIENCED FAILURE OF CRUISE CONTROL AND HORN. DEALERSHIP HAS NOT EXAMINED VEHICLE TO DETERMINE A CAUSE FOR THIS PROBLEM. PLEASE PROVIDE ANY ADDITIONAL INFORMATION / DOCUMENTATION.*AK
AIRBAGS DEACTIVATED. ALSO, VEHICLE HAD NO HORN. AIRBAG LIGHT WAS COMING ON AND OFF.CONTACTED DEALER, AND DEALER STATED CLOCK SPRING WAS DEFECTIVE.*AK
VHEHICLE CAUGHT FIRE NEAR CENTER OF MOTOR BEHIND WHERE YOU PUT IN THE OIL. VEHICLE WAS TAKEN TO LOCAL FORD DEALER FOR RECALL ON THE ACCESSORY POWER CIRCUIT. I RECEIVED A LETTER IN THE MAIL ABOUT THE SWITCH RECALL. THE 94-95 MODELS WHERE ALSO RECALLED DUE AN ELECTRICAL SHORT OUT AT FUEL PUMP RESULTING IN POWER LOSS AND FIRE.…
Read full complaint
VHEHICLE CAUGHT FIRE NEAR CENTER OF MOTOR BEHIND WHERE YOU PUT IN THE OIL. VEHICLE WAS TAKEN TO LOCAL FORD DEALER FOR RECALL ON THE ACCESSORY POWER CIRCUIT. I RECEIVED A LETTER IN THE MAIL ABOUT THE SWITCH RECALL. THE 94-95 MODELS WHERE ALSO RECALLED DUE AN ELECTRICAL SHORT OUT AT FUEL PUMP RESULTING IN POWER LOSS AND FIRE. I BELIVE THIS TO BE WHAT HAPPENED TO MY VAN.I WAS NOT NOTIFIED OF THIS RECALL, NIETHER WAS I INFORMED OF IT WHAN I TOOK THE VAN IN FOR THE OTHER RECALL ON THE SWITCH. CAN YOU TELL ME WHAT TO DO FROM HERE? SHOULD I GO TO THE LOCAL FORD DEALER? *AK
NO SUMMARY LISTED FOR ABOV EVEHICLE. *AK
VEHICLE IS STALLING AT ANY SPEED, AND ANY TIME. DEALER STATED IGNITION MODULE NEEDED TO BE REPLACED. *AK
REMINGTON TIRES (P205/75R14) WERE REPLACED. *SLC
Official recalls
399V028000 · Electrical System:wiring:front Underhood
Feb 9, 1999
VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.
Consequence & remedy
Consequence: HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.
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.
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.