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 reports
Mileage unknown · Oct 17, 2000
Air Bags
WE HAVE JUST MOVED TO ROSWELL, GA FROM WINDER GA. WE KNOW OF OVER 15 PEOPLE WHO HAVE OR HAD THE SAME PROBLEM WITH THE 1994 AEROSTARS CLOCK SPRING IN THE AIR BAG NOT WORKING. WHEN I CONTACTED FORD THAY SAID IT WAS NOT A PROBLEM, MOST PEOPLE HAVE IT REPARIED OR JUST LET IT GO AS I HAVE. IT'S HARD TO COME UP WITH 300 TO 500 DOLLARS…
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WE HAVE JUST MOVED TO ROSWELL, GA FROM WINDER GA. WE KNOW OF OVER 15 PEOPLE WHO HAVE OR HAD THE SAME PROBLEM WITH THE 1994 AEROSTARS CLOCK SPRING IN THE AIR BAG NOT WORKING. WHEN I CONTACTED FORD THAY SAID IT WAS NOT A PROBLEM, MOST PEOPLE HAVE IT REPARIED OR JUST LET IT GO AS I HAVE. IT'S HARD TO COME UP WITH 300 TO 500 DOLLARS ON SOMETHING THAT IS A REPEATED PROBLEM. THIS IS A SAFETY ISSUE FOR US ALL. I NOW HAVE A 2 MONTH OLD GRANDAUGHTER AND FEEL UNSAFE KNOWING THAT THE AIRBAG MAY GO OFF AT ANYTIME OR WILL NOT DEPLOY IF I SHOULD EVER NEED IT. PLEASE LOOK AT ALL REPAIRS ON THIS AND I AM SURE THAT FORD WILL NOT HAVE A COMPLANT LIST... SEEM TO BE PAR FOR THE COURSE. THANKS FOR YOUR HELP. *AK
NHTSA ODI #734571
Mileage unknown · Oct 16, 2000
Power Train
THE SPEEDOMETER CLUSTER QUIT WORKING PAST 100,000 MILES, THERE WAS NO WAY TO TELL THE VEHICLES SPEED. NLM
NHTSA ODI #556110
Mileage unknown · Oct 12, 2000
Electrical System
SMELLED WIRES BURNING AFTER THAT HORN WILL NOT WORK CRUISE CONTROL WILL NOT WORK
NHTSA ODI #734168
Mileage unknown · Oct 10, 2000
Seat Belts
ALL OF THE REAR SHOULDER AND LAP SEATBELTS DO NOT RETRACT IN EVENT OF AN EMERGENCY STOP, WHICH WOULD NOT PROTECT OCCUPANT IN EVENT OF A CRASH. MECHANIC SAID THAT PROBLEM WAS DUE TO A DEFECTIVE WEIGHT. *AK *SLC
NHTSA ODI #872663
Mileage unknown · Aug 31, 2000
Electrical System
HEADLIGHT SWITCH BECAME ERRATIC. WHEN SWITCH WAS REMOVED FOR REPLACEMENT , I BECAME AWARE OF THE HARNESS BLOCK BEING MELTED AND CRACKED AROUND 6 OF THE 9 WIRES. THERE HAS BEEN OTHER PROBLEMS WITH THE AEROSTAR RELATING TO CURRENT DRAW IN OTHER PORTIONS OF THEIR HARNESS. TO ME THIS IS A SAFETY ISSUE AND I WAS VERY DISSAPPOINTED TO…
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HEADLIGHT SWITCH BECAME ERRATIC. WHEN SWITCH WAS REMOVED FOR REPLACEMENT , I BECAME AWARE OF THE HARNESS BLOCK BEING MELTED AND CRACKED AROUND 6 OF THE 9 WIRES. THERE HAS BEEN OTHER PROBLEMS WITH THE AEROSTAR RELATING TO CURRENT DRAW IN OTHER PORTIONS OF THEIR HARNESS. TO ME THIS IS A SAFETY ISSUE AND I WAS VERY DISSAPPOINTED TO FIND FORD QUITE UNCONCERNED WHEN I CONTACTED THEIR CUSTOMER ASSISTANCE LINE.
NHTSA ODI #729662
Mileage unknown · Aug 28, 2000
Air BagsElectrical System
AIRBAG LIGHT FLASHES 32 AND HORN QUIT WORKING
NHTSA ODI #729311
Mileage unknown · Aug 22, 2000
Seat Belts
REAR PASSENGER MIDDLE SEAT BELT WILL NOT RETRACT/RELEASE TO BE USED. BELT HAD BECOME JAMMED IN RETRACTOR. TAKING VEHICLE TO DEALER & MECHANIC WILL TRY TO REPAIR PROBLEM. *AK
NHTSA ODI #868354
Mileage unknown · Aug 4, 2000
Power Train
RECALL REQUIRED THAT THE TRANSFER CASE BE REPAIRED, IT WAS REPLACED WITH A DEFECTIVE ONE. THE ELECTRONIC CLUTCH IN THE NEW TRANSFER CASE STARTED MAKING POPPING SOUNDS AT APPROX. 8057 MILES. PROBLEM REPORTED WHILE UNDER RECALL PART WARRANTEE BUT I WAS TOLD THE TRANSFER CASE WOULD NOT MAKE THAT SOUND. IT DID AND LATER FAILED CA…
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RECALL REQUIRED THAT THE TRANSFER CASE BE REPAIRED, IT WAS REPLACED WITH A DEFECTIVE ONE. THE ELECTRONIC CLUTCH IN THE NEW TRANSFER CASE STARTED MAKING POPPING SOUNDS AT APPROX. 8057 MILES. PROBLEM REPORTED WHILE UNDER RECALL PART WARRANTEE BUT I WAS TOLD THE TRANSFER CASE WOULD NOT MAKE THAT SOUND. IT DID AND LATER FAILED CATASTROPHICALLY. IT WAS DANGEROUS TO DRIVE VEHICLE UNDER THOSE CIRCUMSTANCES, FORD SHOULD REPLACE DEFECTIVE UNIT WITH A GOOD ONE BUT REFUSE TO DO SO. *AK
NHTSA ODI #726602
Mileage unknown · Jul 31, 2000
Seat Belts
FRONT PASSENGER'S SIDE SEAT BELT DOESN'T LOCK. CONSUMER ISN'T ABLE TO BE RESTRAINED WHICH MAKES IT INCONVENIENT. DEALER SAID CONSUMER WAS RESPONSIBLE. DIDN'T HAVE A REASON WHY IT HAPPENED. *AK
NHTSA ODI #866414
Mileage unknown · Jul 24, 2000
Air Bags
AIR BAG LIGHT REMAINS ILLUMINATED, INDICATING A MALFUNCTION WITHIN THE SYSTEM. PROBLEM OCCURRED DUE TO A DEFECTIVE CLOCK SENSOR. *AK THE PROBLEM STARTED AFTER RECALL ON IGNITION PROBLEM WAS FIXED. AIR BAG STARTED BLINKING ON AND OFF. *YH
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.
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.
1994 Ford Aerostar Problems, Complaints & Recalls | Skip That Year
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