IllustrationWHEN APPLYING THE BRAKES THERE IS A VIBRATION PRESENT DUE TO WARPED ROTORS. DEALER HAS TURNED ROTORS TWICE, AND THE PROBLEM STILL EXISTS. *AK
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
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 reportsRECALL 99V029000, IGNITION SYSTEM FAILURE. OWNER HAS BEEN WAITING SINCE MARCH 1999 FOR PARTS ON RECALL. *AK
LEFT FRONT AND RIGHT REAR ALUMINUM TIRE RIMS CRACKED IN FOUR DIFFERENT PLACES, CAUSING FAILURE WHICH COULD RESULT IN INJURY IF TIRE RIM WAS TO FALL OFF. *YC
WHILE BACKING VEHICLE OUT OF PARKING LOT, STEERING WHEEL BROKE IN DRIVER'S HANDS & FELL INTO DRIVER'S LAP. HAD NO CONTROL OF VEHICLE. TURNED VEHICLE OFF & TOWED TO DEALER. *AK
WHEEL RIMS FAILED. AFTER FEELING SEVERE WOBBLE AT SPEED, DRIVER PULLED OVER AND FOUND THE ALUMINUM WHEEL RIM ON FR WHEEL WAS FAILING. 3 OF 4 WHEELS SHOWED SEVERE FRACTURES IN SPOKES. WHEELS ARE ALUMINUM WITH 7 SPOKES. WHEEL TYPE 49 FOR 1996 AREOSTARS. RF HAD 4 COMPLETELY FRACTURED SPOKES AND 1 PARTIAL, WHEEL WAS OUT OF ALIGNMEN…
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WHEEL RIMS FAILED. AFTER FEELING SEVERE WOBBLE AT SPEED, DRIVER PULLED OVER AND FOUND THE ALUMINUM WHEEL RIM ON FR WHEEL WAS FAILING. 3 OF 4 WHEELS SHOWED SEVERE FRACTURES IN SPOKES. WHEELS ARE ALUMINUM WITH 7 SPOKES. WHEEL TYPE 49 FOR 1996 AREOSTARS. RF HAD 4 COMPLETELY FRACTURED SPOKES AND 1 PARTIAL, WHEEL WAS OUT OF ALIGNMENT AND READY TO COME OFF IF DRIVEN FURTHER. THIS WOULD HAVE BEEN A CATASTROPHIC FAILURE AND COMPLETE LOSS OF VEHICLE CONTROL. RR SHOWED 1 SPOKE COMPLETELY FRACTURED AND 2 PARTIALS. LF SHOWED 1 SPOKE PARTIALLY FRACTURED. LR SHOWED NO DEFECTS. THIS VEHICLE IS A FAMILY USE, WITH SOME LIGHT TOWING AND NO ABUSE. NO WHEEL DEFECTS WERE NOTED AT PRIOR FORD DEALER SERVICE 42000 MILES OR BY OWNER AT 48500 MILES. WHEEL FAILURES SEEM TO BE SUDDEN. NO ROAD HAZZARDS WHERE INVOLVED. FORD DEALER IS HOLDING FAILED RIMS.
WHILE DRVING VAN AT ANY SPEED A GRINDING NOISE COMES FROM THE RIGHT FRONT WHEEL. WHEN THE VAN WAS CHECKED BY A MECHANIC THE BEARING WAS GONE FROM THE SPINDLE. PLEASE LIST VIN, MILEAGE AND DATES FOR OTHER VANS. *AK
AFTER PARKING VEHICLE AND APPYLING THE EMERGENCY PARKING BRAKE, A PIN WITHIN THE HANDLE ASSEMBLY BROKE, CAUSING THE VEHICLE TO ROLL FORWARD. PLEASE GIVE ANY FURTHER DETAILS. *AK
CONSUMER CONTACTED THE DEALER IN REFERENCE TO NHTSA RECALL 99V029000 AND MFR RECALL 99S02, IGNITION SWITCH FAILURE. DEALER STATED PARTS WERE NOT AVAILABLE. PLEASE PROVIDE ANY FURTHER DETIALS. RECALL HAS YET TO BE CORRECTED. *AK
VEHICLE EXPERIENCED FAILURE OF THE IDLE AIR CONTROL VALVE/MOTOR CAUSING AIR BYPASS TO STICK. MJS
ON APRIL 19, 1999, QUALITY OF NAPA LOCATED AT 1823 SOSCOL AVE, NAPA, 94559, PERFORMED OUR 30,000 MILE SERVICE WHICH IN OUR FORD MAINTENANCE SCHEDULE BOOK INCLUDES INSPECTION OF DISC BRAKE SYSTEM AND DRUM BRAKE SYSTEM. ON APRIL 19TH, OUR MILEAGE WAS 34,712.5 AND QUALITY SIGNED OFF ON THE MAINTENANCE SCHEDULE FOR BOTH THE 30,000 &…
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ON APRIL 19, 1999, QUALITY OF NAPA LOCATED AT 1823 SOSCOL AVE, NAPA, 94559, PERFORMED OUR 30,000 MILE SERVICE WHICH IN OUR FORD MAINTENANCE SCHEDULE BOOK INCLUDES INSPECTION OF DISC BRAKE SYSTEM AND DRUM BRAKE SYSTEM. ON APRIL 19TH, OUR MILEAGE WAS 34,712.5 AND QUALITY SIGNED OFF ON THE MAINTENANCE SCHEDULE FOR BOTH THE 30,000 & 35,000 MILE SERVICE. ON OR ABOUT MAY 17TH, 1999 OUR BRAKES FAILED AT 35,597 MILES, AND CAUSED US TO TAKE OUR VAN TO FORD FOR TROUBLESHOOTING. FORD CHARGED US OVER $500 TO REPLACE THE BRAKES. OUR COMPLAINT IS WITH QUALITY, THEY SIGNED OUR BOOK RECOGNIZING PART OF SERVICING ON 4/19 WAS BRAKE INSPECTION AND DIDN'T INFORM US OF OUR BRAKES BEING IN NEED OF REPLACEMENT AT THAT TIME. THUS RESULTING IN BRAKE FAILURE AND FURTHER DAMAGE TO THE BRAKE SYSTEM CAUSING US TO PAY IN EXCESS OF $500 IN REPAIRS. PLEASE CONTACT ME WITH REGARD TO THIS COMPLAINT. I WISH TO FURTHER PURSUE THIS COMPLAINT AS WELL. THANK-YOU, KATHLEEN. *AK
Official recalls
499V029000 · 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
2EA99002 · 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