IllustrationSMELL OF GAS FUME FROM INSIDE THE VEHICLE GRADUALLY BECAME WORSE AND INTOLERABLE. DEALER CORRECTED PROBLEM BY REPLACING THE FUEL PUMP GASKET.
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
What owners actually said
257 reportsTRANSFER CASE HAS REPEATEDLY LEAKED AND EVENTUALLY BLEW. IT HAS BEEN WORKED ON/REPLACED 8 TIMES. STILL LEAKING AFTER RECALL REPLACEMENT (97V204000). DEALER REFUSES TO REPLACE UNDER WARRANTY DUE TO THEIR 12 MONTHS/12000MI PARTS POLICY. *AK
ABS SYSTEM WARNING LIGHT SWITCH WAS DEFECTIVE, AND WIRING MELTED AND COULD NOT REGISTER WHEN BRAKES WERE WORN OUT. DEALER CONTACTED, AND PROBLEM WAS REMEDIED. VEHICLE DID NOT COMPLY TO RECALL 98E010000. PROVIDE FURTHER INFORMATION. *AK
WHILE DRIVING THE THE RIGHT FRONT WHEEL LOCKED UP, CAUSING THE VEHICLE TO SKID. CAUSE UNKNOWN. PLEASE GIVE ANY FURTHER DETAILS. *AK
RECALL 99VO29, IGNITION SWITCH SHORT. DEALER WILL NOT REPAIR UNTILL 5/3/99. *AK
SUSPECT UNDERLYING PROBLEM WITH AIRBAG CIRCUITRY. AIRBAG LIGHT BLINKS 3/2. THIS WAS FIRST REPAIRED UNDER WARRANTY BY DEALER HOLLYWOOD LINCOLN MERCURY IN HOLLYWOOD, FLORIDA UNDER WARRANTY LESS THAN 2 YEARS AGO. THE CLOCKSPRING MECHANISM WAS REPLACED. NOW AGAIN THE AIRBAG LIGHT BLINKS 3/2, AND DIAGNOSTICS WITH THE SAME DEALER REVE…
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SUSPECT UNDERLYING PROBLEM WITH AIRBAG CIRCUITRY. AIRBAG LIGHT BLINKS 3/2. THIS WAS FIRST REPAIRED UNDER WARRANTY BY DEALER HOLLYWOOD LINCOLN MERCURY IN HOLLYWOOD, FLORIDA UNDER WARRANTY LESS THAN 2 YEARS AGO. THE CLOCKSPRING MECHANISM WAS REPLACED. NOW AGAIN THE AIRBAG LIGHT BLINKS 3/2, AND DIAGNOSTICS WITH THE SAME DEALER REVEAL ANOTHER BAD CLOCKSPRING AS WELL AS A BAD MONITOR. EMAILS TO FORD ARE TO NO AVAIL. THEY REMAIN NON-RESPONSIVE TO MY POSITION THAT A FUNDAMENTAL PROBLEM EXISTS WITH THE AIRBAG CIRCUITRY WHICH THEY NEVER CORRECTED OR REVEALED. FORD HAS NOT DISPUTED ANY FACTS OF CORRESPONDENCE. I BELIEVE A PUBLIC SAFETY ISSUE EXISTS BECAUSE A FAULTY AIRBAG CIRCUIT CAUSES REPEATED AIRBAG MALFUNCTION. THERE MIGHT ALSO BE A CONNECTION TO A RECENTLY RECEIVED FORD NOTICE TO CORRECT A FIRE HAZARD SHORT IN NEARBY STEERING COLUMN IGNITION CIRCUITRY. PLEASE INVESTIGATE FOR POSSIBLE RECALL DUE TO THE AIRBAG MALFUNCTION. *AK
ON THE DATE LISTED MY PASSENGER SIDE FRONT WHEEL/TIRE FELL OFF. THIS IS MY WIFE'S WORK CAR AND SHE THOUGHT SHE COULD HEAR SOMETHING DIFFERENT. SO I DROVE IT TO WORK THE NEXT DAY. I THOUGHT I COULD FEEL SOME ROUGHNESS SIGHTLY THROUGH MY PEDAL BUT IT WOULD COME AND GO. I THOUGHT IT COULD BE A U-JOINT PROBLEM. ANYWAY AS I WAS …
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ON THE DATE LISTED MY PASSENGER SIDE FRONT WHEEL/TIRE FELL OFF. THIS IS MY WIFE'S WORK CAR AND SHE THOUGHT SHE COULD HEAR SOMETHING DIFFERENT. SO I DROVE IT TO WORK THE NEXT DAY. I THOUGHT I COULD FEEL SOME ROUGHNESS SIGHTLY THROUGH MY PEDAL BUT IT WOULD COME AND GO. I THOUGHT IT COULD BE A U-JOINT PROBLEM. ANYWAY AS I WAS TURNING A SHARP TURN IN THE TOWN OF OF MEROM, IN THE WHEEL FELL OFF WITH THE BRAKE LINE STILL CONNECTED. THE SPINDLE HAD SNAPPED INTO BECAUSE THE BEARING LOCKED UP DUE TO INADEQUATE PACKING GREASE. THIS VAN IS MY FAMILY CAR AND THIS COULD HAVE BEEN A DISASTEROUS ACCIDENT IF THE WHEEL HAD COME OFF ON THE OPEN HIGHWAY. I DO HAVE THE WHEEL BEARING IN MY POSSESSION. THE OUTER COLLAR IS MISSING BUT THE INDIVIDUAL BEARING ROLLARS ARE WELDED TO THE INNER COLLAR AS IS THE PIECE OF SPINDLE SHAFT THAT SHEARED OFF. I JUST THOUGHT THIS SHOULD BE BROUGHT TO SOMEBODIES ATTENTION.
TRANSFER CASE FAILED PRIOR TO RECALL NOTICE, HOWEVER REPAIR IS NOT SUFFICIENT OR PROPER, ORIGINAL TRANSFER CASE REPLACED WITHOUT THE ALUMINUM DRIVESHAFT INSTALLATION.
IGNITION SWITCH SHORT CIRCUIT CAUSED WIRING TO OVERHEAT AND BURN IN STEERING COLUMN AREA.
NO SUMMARY.
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.