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 · Jul 18, 2000
Engine And Engine CoolingPower Train
TRANSFER CASE PROBLEMS BEGAN WHEN FLUID WAS LEAKING. TOOK TO MECHANIC, WHO REPLACED THE GASKETS. ABOUT A MONTH LATER THE TRANSMISSION WENT OUT, AND WAS REBUILT BY DIFFERENT MECHANIC. FLUID CONTINUED TO LEAK, GASKETS WERE REPLACED A SECOND TIME. FLUID SPEWED DURING DRIVING, WHICH MECHANIC SAID WAS DUE TO CATALYTIC CONVERTER B…
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TRANSFER CASE PROBLEMS BEGAN WHEN FLUID WAS LEAKING. TOOK TO MECHANIC, WHO REPLACED THE GASKETS. ABOUT A MONTH LATER THE TRANSMISSION WENT OUT, AND WAS REBUILT BY DIFFERENT MECHANIC. FLUID CONTINUED TO LEAK, GASKETS WERE REPLACED A SECOND TIME. FLUID SPEWED DURING DRIVING, WHICH MECHANIC SAID WAS DUE TO CATALYTIC CONVERTER BLOWING HOT AIR ON TRANSMISSION FLUID, CAUSING ITS RELEASE. REPLACED CATALYTIC CONVERTER. FLUID STILL CONTINUED TO SPEW, ALL OVER THE UNDERSIDE OF THE VEHICLE. IT WAS DRIVEN 120 MILES, A QT. OF TRANSMISSION FLUID ADDED, AND BACK 120 MILES, WITH ANOTHER QT. ADDED. MECHANIC TAKES TRANSFER CASE APART, FINDING THE BEARINGS WORN TO A NON-ROUND SHAPE, AND THE SHAFT END WORN DOWN. CHECKED FOR RECALL, AND THERE IS ONE, 99V094000 BUT FORD SAYS OUR VAN DOESN'T FALL INTO THIS RECALL AND REFUSES TO HELP.
NHTSA ODI #725657
Mileage unknown · Jun 16, 2000
Service Brakes, Hydraulic
CONSUMER WAS DRIVING AND WHEN APPLYING BRAKES THERE WAS A GRINDINDG NOISE. MECHANIC TOLD HER THAT THERE WAS METAL TO METAL GRINDING SOUND ON THE ROTORS. THAT WAS WHY SHE WAS HEARING THE GRINDING NOISES. *AK
NHTSA ODI #863702
Mileage unknown · Jun 14, 2000
Air BagsSeat BeltsCrash
EMPLOYEE FATALLY INJURED IN CRASH 06/05/00. AIR BAG DID NOT DEPLOY. AIR BAG SENSOR APPEARS TO HAVE BEEN REPLACED IN MARCH 2000, AFTER COMING ON AND BLINKING. COLLISION WAS WITH A FIXED OBJECT AT APPROXIMATELY 30-40 MPH, ON LEFT FRONT CORNER OF VEHICLE. HAVE THERE BEEN SIMILAR FAILURES REPORTED?*AK FROM THE ACCIDENT REPORT I…
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EMPLOYEE FATALLY INJURED IN CRASH 06/05/00. AIR BAG DID NOT DEPLOY. AIR BAG SENSOR APPEARS TO HAVE BEEN REPLACED IN MARCH 2000, AFTER COMING ON AND BLINKING. COLLISION WAS WITH A FIXED OBJECT AT APPROXIMATELY 30-40 MPH, ON LEFT FRONT CORNER OF VEHICLE. HAVE THERE BEEN SIMILAR FAILURES REPORTED?*AK FROM THE ACCIDENT REPORT IT APPEARED THAT THE DRIVER LOST CONTROL OF THE VEHICLE WHILE IT WAS RAINING. THE VEHICLE LEFT THE ROAD, ROTATED COUNTERCLOCKWISE AND LANDED ON THE PASSENGER SIDE NEXT TO A UTILITY POLE IN HEAVY BRUSH. THE DRIVER WAS EJECTED FROM THE VEHICLE AT THE POINT OF IMPACT WITH THE CULVERT. UPON INVESTIGATION AT THE SCENE A TROOPER NOTICED THAT THE DRIVER'S SEAT BELT WAS UNBUCKLED AND THAT THE AIR BAG DID NOT DEPLOY. IT WAS DEEMED THAT THE DRIVER WAS NOT SPEEDING BUT WAS MOST LIKELY DRIVING TOO FAST FOR THE ROAD CONDITIONS. *NLM
NHTSA ODI #724005
Mileage unknown · Jun 1, 2000
Fuel System, Other
NO MATTER HOW MUCH GAS IS IN THE TANK, GAS SENSOR MISREADS IT. IT COULD READ FULL OR ANYWHERE IN BETWEEN.*AK
NHTSA ODI #862864
Mileage unknown · May 22, 2000
Electrical System
UPON STARTING VEHICLE CONSUMER NOTICED SMOKE COMING FROM THE STEERING COLUMN. CONSUMER CONTACTED THE DEALER, DEALER REPLACED THE ELECTRICAL WIRING HARNESS. ALSO, WHEN VEHICLE WAS IN THE OFF POSITION, IT CONTINUED TO RUN, CAUSING THE BATTERY TO DIE OUT. PLEASE PROVIDE ANY FURTHER DETAILS. *AK
NHTSA ODI #862287
Mileage unknown · May 22, 2000
Power Train
VEHICLE WOULD NOT TRAVEL OVER 35 MPH. TRANSMISSION HAS BEEN REBUILT TWO TIMES.HOWEVER, PROBLEM RETURNED AFTER REPAIRS. PLEASE PROVIDE FURTHER INFORMATION. *AK
NHTSA ODI #862247
Mileage unknown · May 17, 2000
Air BagsElectrical SystemVehicle Speed Control
HORN ASSEMBLY/AIR BAG INDICATOR LIGHT, AND CRUISE CONTROL WENT OUT AT SAME TIME. DEALER HAS BEEN CONTACTED.PLEASE PROVIDE FURTHER INFORMATION. *AK
NHTSA ODI #862034
Mileage unknown · Apr 11, 2000
Power Train
WHILE DRIVING VEHICLE HESITATED FOR ABOUT 40 SECONDS. DEALER FLUSHED OUT FLUID AND IT GOT WORSE. CONSUMER SAID IT WAS THE EXACT RECALL LISTED ON WEB. *AK
NHTSA ODI #860072
Mileage unknown · Apr 6, 2000
Engine And Engine Cooling
WE WOULD LIKE TO KNOW IF THERE HAVE BEEN ANY OTHER COMPLAINTS OF ENGINE FAILURE AS A RESULT OF A DEFECT OR LEAK IN THE TIMING CASE GASKET OF THIS VEHICLE. WE FEEL THIS LEAK DIRECTLY RESULTED IN THE FAILURE OF THE ENGINE WHICH WE NOW HAVE TO REPLACE AT GREAT EXPENSE. AFTER CONTACTING FORD, THE MANUFACTURER OF OUR MINIVAN, WE FI…
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WE WOULD LIKE TO KNOW IF THERE HAVE BEEN ANY OTHER COMPLAINTS OF ENGINE FAILURE AS A RESULT OF A DEFECT OR LEAK IN THE TIMING CASE GASKET OF THIS VEHICLE. WE FEEL THIS LEAK DIRECTLY RESULTED IN THE FAILURE OF THE ENGINE WHICH WE NOW HAVE TO REPLACE AT GREAT EXPENSE. AFTER CONTACTING FORD, THE MANUFACTURER OF OUR MINIVAN, WE FIND THAT WE HAVE NO RECOURSE IN THIS MATTER OTHER THAN TO CONTACT YOU AND MAKE IT PART OF YOUR RECORDS THAT THIS HAS HAPPENED TO OUR VEHICLE. WE WOULD APPRECIATE HEARING FROM YOU AS TO WHETHER OR NOT ANY OTHER REPORTS SIMILAR TO OURS HAVE BEEN MADE WITH REGARD TO THE L994 FORD AEROSTAR 2WD, 3.0L VEHICLE. THANK YOU. *AK
NHTSA ODI #721100
Mileage unknown · Apr 5, 2000
Air BagsCrashInjury
WHILE DRIVING CONSUMER SMELLED A STRONG ODOR COMING FROM THE AIRBAG, CONSUMER STARTED SNEEZING. THEN THE SNEEZING GOT WORSE, AND CONSUMER BLACKED OUT, RESULTING IN A CRASH. TOOK VEHICLE TO DEALER, AND THEY SAID IT WAS LIKELY THAT THE BAG WAS LEAKING. *AK
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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