← New search

1996 Ford Aerostar

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 1996 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

Other model years Selected 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: 14 of 104 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.

  • Wheels. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports4 fire reports6 injury reports

What owners actually said

104 reports
Mileage unknown · Sep 12, 2002
Service Brakes, Hydraulic

BRAKE ROTORS ARE WEARING, AND WHEN THE CONSUMER APPLIES THE BRAKES, THE VEHICLE WILL JERK AND BECOME HARD FOR THE CONSUMER TO CONTROL. THE DEALER WAS NOTIFIED. *AK THE CONSUMER STATES THAT THIS IS A RESULT OF WARPED FRONT BRAKE DISC. (FORD WON'T PAY) *SCC

NHTSA ODI #8018497

Mileage unknown · Aug 1, 2002
Air BagsCrashInjury

VAN INVOLVED IN HEAD ON COLLISION WHILE SITTING STILL. SPEED FROM OTHER VEHICLE ESTIMATED AT 40 MPH. AIR BAG FAILED TO DEPLOY UPON COLLISION. IMPACT WAS TO EXTENT OF FRAME BEING KNOCKED OUT OF LINE. PLEASE DESCRIBE DETAILS. *AK

NHTSA ODI #8015295

Mileage unknown · Jul 29, 2002
Service Brakes, Hydraulic

WHILE DRIVING, VEHICLE WILL JERK FORWARD. THIS IS CAUSED BY FRONT ROTORS WARPING EXTREMELY. DEALER CONTACTED.*AK THE BRAKE PADS ARE BARELY WORN. CONSUMER WAS ADVISED BY FORD THAT THE WARRANTY HAD EXPIRED AND THERE WAS NOTHING THEY COULD DO. CONSUMER FEELS THE ROTORS WARPED PREMATURELY. *JG

NHTSA ODI #8014952

Mileage unknown · Jul 20, 2002
Tires

THESE 2 TIRE FAILURES OCCURRED UNDER NORMAL DRIVING CIRUCUMSTANCES ON A VEHICLE THAT IS REGULARLY MAINTAINED AT THE FIRESTONE SERVICE CENTER THAT INSTALLED THE TIRES. FIRESTONE HAS DENIED CLAIM OF VEHICLE REPAIR FROM THE TIRE SEPARATION INCIDENT ON JUNE 16, 2002, SAYING THE 'TIRE WAS IMPROPERLY INFLATED FOR AN UNDETERMINED TIM…

Read full complaint

THESE 2 TIRE FAILURES OCCURRED UNDER NORMAL DRIVING CIRUCUMSTANCES ON A VEHICLE THAT IS REGULARLY MAINTAINED AT THE FIRESTONE SERVICE CENTER THAT INSTALLED THE TIRES. FIRESTONE HAS DENIED CLAIM OF VEHICLE REPAIR FROM THE TIRE SEPARATION INCIDENT ON JUNE 16, 2002, SAYING THE 'TIRE WAS IMPROPERLY INFLATED FOR AN UNDETERMINED TIME PERIOD'. THEIR OWN PEOPLE INSPECTED THE TIRES 40 DAYS PRIOR, THE TIME OF THE 1ST TIRE SEPARATION, CLAIMING TIRES TO BE WORTHY, PROPERLY INFLATED ETC. WE FIRMLY BELIEVE THAT AN INVESTIGATION INTO THESE TIRES MUST HAPPEN, IF IT ISNT ALREADY UNDERWAY. THIS WAS A POTENTIALLY DANGEROUS SITUATION THAT FORTUNATELY DID NOT END TRAGICALLY, OTHER THAN DOLLARS SPENT OUT OF OUR POCKET. PLEASE TAKE SERIOUS NOTE TO OUR CIRCUMSTANCE, IT CAN NOT BE COMMON OF TIRES THAT 2 WOULD SEPARATE IN 40 DAYS ON A REGULARLY MAINTAINED VEHICLE ON A CLEAR HIGHWAY AND SPEEDS UNDER NORMAL HIGHWAY SPEED LIMITS. AFTER THE FIRST TIRE FAILURE, THE SERVICE CENTER MANAGER STATED THAT THE 'TIRE HAD SEPARATED AND FAILED'. AFTER THE SECOND SEPARATION, THE SAME MANAGER HAD THE SAME STATEMENT FOR THE SECOND TIRE. THEY ULTIMATELY WERE WILLING TO REPLACE ALL 4 TIRES WITH A BRIDGESTONE PRODUCT, FOR US, THAT WAS UNACCEPTABLE, WE CHOOSE TO TAKE OUR BUSINESS ELSEWHERE (CLEARLY, NOT AN ISSUE FOR THE NHTSA). THOUGH, WHAT IS OF GREAT CONCERN TO US IS THE LACK OF URGENCY ON THE PART OF LOCAL FIRESTONE AND CORPORATE FIRESTONE THAT THERE COULD POTENTIALLY BE A SERIOUS PROBLEM WITH A PRODUCT THEY SELL.THANK YOU IN ADVANCE FOR YOUR TIME, YOUR PROMPT RESPONSE, AND YOUR CONSIDERATION.*AK

NHTSA ODI #764493

Mileage unknown · Apr 15, 2002
Wheels

ALUMINIUM WHEELS HAVE CRACKS IN THEM. DEALER NOTIFIED.*AK *TT

NHTSA ODI #8007666

Mileage unknown · Jan 8, 2002
Wheels

THREE OF ORIGINAL ALUMINUM SPOKE WHEELS HAVE BROKEN ACROSS THE SPOKES. DEALER/ MANUFACTURER CONTACTED. *AK *JG

NHTSA ODI #8001780

Mileage unknown · Jan 3, 2002
Wheels

THE RIGHT FRONT WHEEL HAS FATIGUE CRACKS AROUND LUG NUT HOLES, CHP SUGGEST THAT WE CONTACT YOU, COULD BE A SAFETY ISSUE. *AK

NHTSA ODI #756355

Mileage unknown · Jan 2, 2002
Electrical SystemUnknown Or Other

3 MONTHS AGO, I BROUGHT OUR VAN TO THE LOCAL DEALER BECAUSE THE CHECK ENGINE LIGHT WAS ON. THEY SAID THE PROBLEM WAS A FAULTY SPARK-PLUG WIRE, WHICH THEY REPLACED AND RESET THE COMPUTER, FOR $130.00. A MONTH LATER, THE VAN STARTED HAVING ENGINE PROBLEMS, SO I HAD ANOTHER GARAGE DIAGNOSE THE PROBLEM, AND THEY SAID THERE WAS A H…

Read full complaint

3 MONTHS AGO, I BROUGHT OUR VAN TO THE LOCAL DEALER BECAUSE THE CHECK ENGINE LIGHT WAS ON. THEY SAID THE PROBLEM WAS A FAULTY SPARK-PLUG WIRE, WHICH THEY REPLACED AND RESET THE COMPUTER, FOR $130.00. A MONTH LATER, THE VAN STARTED HAVING ENGINE PROBLEMS, SO I HAD ANOTHER GARAGE DIAGNOSE THE PROBLEM, AND THEY SAID THERE WAS A HEAD GASKET PROBLEM, AND POSSIBLY A CRACKED HEAD. I TOOK THE VAN TO A TOP MECHANIC, WHO REMOVED THE HEADS AND HAD THEM INSPECTED. RESULTS WERE THAT THEY WERE BOTH CRACKED. WE NEVER RAN THE VAN HOT, AND KEPT THE VAN IN GOOD RUNNING SERVICE. WE RARELY WENT OUT OF TOWN, SO THE VAN WAS USED ABOUT 20-25 MILES A DAY. MY MECHANIC SAYS THE ENGINE WAS RUN HOT, AND HE FEELS ALL FORD AEROSTARS HAVE AN INHERENT PROBLEM OF RUNNING TOO HOT, OVER TIME, DUE TO THE AIR/FUEL MIX DURING COMBUSTION. OUR VAN IS THE 5TH AEROSTAR THEY'VE REPLACED HEADS ON IN THE PAST 2 MONTHS. WE'RE OUT $1400.00 FOR THIS REPAIR.

NHTSA ODI #756320

Mileage unknown · Dec 21, 2001
Engine And Engine Cooling

ENGINE WAS NOT RUNNING PROPERLY. TOOK VEHICLE TO DEALER, AND THEY STATED THAT HEAD GASKET NEEDED TO BE REPLACED. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK

NHTSA ODI #8001038

Mileage unknown · Dec 18, 2001
Exterior Lighting

HEADLIGHT SWITCH AND DIMMER SWITCH MALFUNCTIONED, AND HAVE BEEN REPLACED TWICE. CONSUMER NOTED THAT HEADLIGHT SWITCH CURRENTLY NEEDED TO BE REPLACED. *AK

NHTSA ODI #8000871

Official recalls

4

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.

96V161000 · Equipment:other:labels

Aug 29, 1996

THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence & remedy

Consequence: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .

Remedy: OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.

96V070000 · Latches/locks/linkages:doors:latch

Apr 22, 1996

WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."

Consequence & remedy

Consequence: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.

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

2

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