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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 →

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 reports
Mileage unknown · Apr 2, 2001
Air BagsCrash

VEHICLE WAS INVOLVED IN A FRONTAL COLLISION AT45MPH. UPON IMPACT, AIRBAGS DID NOT DEPLOY.*AK

NHTSA ODI #884817

Mileage unknown · Mar 29, 2001
Structure

BOLTS HOLDING HYDRAULIC CYLINDER BROKE RIGHT OFF ON BACK LIFT DOOR. WHEN IT BROKE, IT FELL RIGHT ON CONSUMER'S HEAD. CONTACTED DEALER, AND THEY WERE WILLING TO FIX PROBLEM AT OWNER'S EXPENSE.*AK

NHTSA ODI #884563

Mileage unknown · Feb 20, 2001
Wheels

LEFT REAR ALLOY WHEEL WAS CRACKED WITHIN ONE OF THE SPOKES. DEALER/MANUFACTURER NOTIFIED, AND INFORMED THAT IT WAS OUT OF ITS WARRANTY AND NOTHING WILL DE DONE. *AK THE DEALER INSPECTED THE WHEEL AND CONCLUDED THAT THE WHEEL WAS DEFECTIVE. *YH

NHTSA ODI #880888

Mileage unknown · Feb 20, 2001
StructureInjury

LEFT LIFTGATE SUPPORT FAILED, RIGHT ONE FAILED 2 MONTHS LATER. *AK THE FIRST FAILURE INJURED THE CONSUMER. *YH

NHTSA ODI #880813

Mileage unknown · Jan 30, 2001
Seat Belts

SHOULDN'T SEAT BELTS LAST FOR THE LIFE OF THE VEHICLE? *AK

NHTSA ODI #740196

Mileage unknown · Jan 9, 2001
Electrical SystemEngine And Engine CoolingEquipment

REMINGTON TIRES (P205/75R14) WERE REPLACED. *SLC

NHTSA ODI #558844

Mileage unknown · Jan 8, 2001
Tires

WHILE TRAVELING 65MPH ON HIGHWAY FRONT DRIVER'S SIDE TIRE BLEWOUT. A FEW DAYS LATER, DRIVER'S REAR TIRE. P215/70R14, DOTVDHYJBA48, AFTER MARKET TIRES ON USED VEHICLE. *AK

NHTSA ODI #877675

Mileage unknown · Nov 21, 2000
Air BagsFuel System, Gasoline

AIRBAG LIGHT FLASHES, THER IS A PATTERN, IT COMES ON INTERMITTENTLY. ALSO, FUEL PUMP WAS REPLACED BY THE DEALERSHIP. *AK

NHTSA ODI #875363

Mileage unknown · Nov 20, 2000
Electrical System

WHILE DRIVING ON FREEWAY AT 60 MPH ENGINE QUIT 100%. CONSUMER PULLED OVER, AND HAD VEHICLE TOWED TO A NEAR BY MECHANIC. THEY SAID IT WAS A SHORT JUST BEFORE IGNITION SWITCH, THERE WAS AN ELECTRICAL OVERLOAD WIRING HARNESS THAT PRODUCED TOO MUCH HEAT WHICH CAUSED LOSS OF POWER TO THE ENGINE. *AK

NHTSA ODI #875249

Mileage unknown · Oct 24, 2000
Tires

FIRESTONE TIRES EXPERIENCED A BLOWOUT AND CAUSED DAMAGE TO THE VEHICLE, LATER THE VEHICLE DEVELOPED A SHIMMY IN THE FRONT OF THE VAN AND THE DEALER ADVISED THAT IT WAS THE TIRES, THE CONSUMER IS REQUESTING REIMBURSEMENT FOR REPLACING THE TIRES. *SLC

NHTSA ODI #556816

Official recalls

3

99V028000 · 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

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.