RecallMyCar

Ford Aerostar Recalls & Complaints by Model Year

NHTSA lists 23 safety recalls and 2,311 owner complaints across 15 model years of the Ford Aerostar (1986–2000). The most-complained-about year is 1993.

23
safety recalls, all years
2,311
owner complaints, all years
1986
year with most recalls
1993
year with most complaints

Pick your Ford Aerostar model year

Model yearRecallsComplaints
2000 Ford Aerostar06
1999 Ford Aerostar07
1998 Ford Aerostar04
1997 Ford Aerostar363
1996 Ford Aerostar4104
1995 Ford Aerostar5157
1994 Ford Aerostar3257
1993 Ford Aerostar2374
1992 Ford Aerostar3317
1991 Ford Aerostar3223
1990 Ford Aerostar6195
1989 Ford Aerostar5260
1988 Ford Aerostar4177
1987 Ford Aerostar4114
1986 Ford Aerostar753

What Ford Aerostar owners complain about

Across all model years, owners have filed 2,311 complaints with NHTSA. The 1993 model year has the most, with 374.

All Ford Aerostar recalls (23)

Every NHTSA safety campaign that lists a Ford Aerostar, most recent first, with the model years each one covers.

  1. Cables (vehicle speed control)

    NHTSA 00V425000 Reported 36,500 vehicles potentially affected FORD MOTOR COMPANY

    Vehicle description: minivans equipped with 3.0l engines. An accelerator cable was kinked during installation, causing the core wires to eventually fray.

    Remedy: Dealers will install a new accelerator cable.

    Model years: 1997

  2. Transfer case (4-wheel drive) (power train)

    NHTSA 99V094000 Reported 10,951 vehicles potentially affected FORD MOTOR COMPANY

    Vehicle description: all wheel drive passenger minivans. (this includes all 1992 AWD aerostars not previously included in safety recall 97v-204/97s83). 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…

    Remedy: Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

    Model years: 1992

  3. Switch (electrical system)

    NHTSA 99V029000 Reported 762,201 vehicles potentially affected FORD MOTOR COMPANY

    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.

    Remedy: Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

    Model years: 1992, 1993, 1994, 1995, 1996, 1997

  4. Electrical system: front underhood

    NHTSA 99V028000 Reported 23,097 vehicles potentially affected FORD MOTOR COMPANY

    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.

    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.

    Model years: 1994, 1995

  5. Tank assembly (fuel system)

    NHTSA 98V190000 Reported 140,000 vehicles potentially affected FORD MOTOR COMPANY

    Vehicle description: MINI vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada…

    Remedy: Dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. This coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road…

    Model years: 1988, 1989, 1990

  6. Transfer case (4-wheel drive) (power train)

    NHTSA 97V204000 Reported 75,000 vehicles potentially affected FORD MOTOR COMPANY

    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,…

    Remedy: Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

    Model years: 1992, 1993, 1994, 1995, 1996, 1997

  7. Labels (equipment)

    NHTSA 96V161000 Reported 134,770 vehicles potentially affected FORD MOTOR COMPANY

    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."

    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.

    Model years: 1996

  8. Ignition (electrical system)

    NHTSA 96V071000 Reported 7,900,000 vehicles potentially affected FORD MOTOR COMPANY

    The ignition switch could experience an internal short circuit.

    Remedy: Dealers will replace the ignition switch.

    Model years: 1988, 1989, 1990, 1991

  9. Latch (latches/locks/linkages)

    NHTSA 96V070000 Reported 73,500 vehicles potentially affected FORD MOTOR COMPANY

    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."

    Remedy: Dealers will inspect and, if necessary, replace the driver door latch.

    Model years: 1996

  10. Labels (equipment)

    NHTSA 95V037000 Reported 12,000 vehicles potentially affected FORD MOTOR COMPANY

    The certification label on these vehicles have incorrect rear tire sizes listed. P215/70r14sl should be p215/75r14sl. This does not comply with FMVSS no. 120, "tire selection and rims for motor vehicles other than passenger cars."

    Remedy: Owners will be mailed a supplementary label containing the correct rear tire information and instructions for installing the label on their vehicles. If owners prefer, their dealer can install the label for them.

    Model years: 1995

  11. Carrier/rack (equipment)

    NHTSA 94V239000 Reported 9,400 vehicles potentially affected FORD MOTOR COMPANY

    The spare tire supplied with the vehicle can contact the brake lines on the rear axle if it is mounted in the underbody spare tire carrier. Such contact could result in fracture of a rear brake line.

    Remedy: Dealers will install a lower profile MINI-spare tire on the existing MINI-spare wheel. The new tire will allow the MINI-spare to be installed with appropriate clearances in the underbody spare tire carrier.

    Model years: 1995

  12. Automatic transmission (power train)

    NHTSA 91V189000 Reported 792,000 vehicles potentially affected FORD MOTOR COMPANY

    When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.

    Remedy: Repair the transmission with a new park pawl.

    Model years: 1989, 1990, 1991

  13. Anchorage (seat belts)

    NHTSA 91V164000 Reported 4,842 vehicles potentially affected SHERROD VANS, INC.

    Seat belt anchorage bar for rear sofa failed to sustain loads required by FMVSS 210.

    Remedy: Replace noncomplying sofa bar with bar that meets requirements.

    Model years: 1989, 1990, 1991

  14. Support device/strut (structure)

    NHTSA 91V136000 Reported 112,000 vehicles potentially affected FORD MOTOR COMPANY

    Some liftgate gas cylinder-to-body attachment ball studs may fracture in either the open or closed position.

    Remedy: Replace the gas cylinder-to-body attachment ball studs.

    Model years: 1987, 1988

  15. Recliner (seats)

    NHTSA 90V144000 Reported 14,300 vehicles potentially affected FORD MOTOR COMPANY

    The second row right hand seat assembly has a tilt forward function. A latch retains the seat in the normal ride postion, and this latch may release under severe frontal impact conditions, allowing the seat to pivot forward.

    Remedy: Replace seat pawl assembly with a revised design assembly.

    Model years: 1989, 1990

  16. Filler pipe and cap (fuel system)

    NHTSA 90V021000 Reported 91,000 vehicles potentially affected FORD MOTOR COMPANY

    Insufficient interference fit between fuel tank filler pipe and grommet could result in an inadequate seal which could allow fuel to seep from the joint.

    Remedy: Install a revised design grommet.

    Model years: 1986

  17. Anchorage (seat belts)

    NHTSA 89V226000 Reported 118,787 vehicles potentially affected FORD MOTOR COMPANY

    Vans were produced without plastic cover designed to cover outboard seat back pivot hinge allowing webbing of front passenger-side safety belts to become abraded or cut due to contact with exposed hinge.

    Remedy: Install plastic pivot cover; replace belts as necessary.

    Model years: 1986, 1987

  18. Master cylinder (service brakes)

    NHTSA 89V223000 Reported 30,000 vehicles potentially affected FORD MOTOR COMPANY

    Inability to maintain pressure in the secondary system of the master cylinder (controls braking of rear wheels) could increase brake pedal travel and reduce brake performance at temperatures less than 40 degrees.

    Remedy: Install new design master cylinder incorporating a redesigned seal.

    Model years: 1990

  19. Seats

    NHTSA 88V145000 Reported 90,000 vehicles potentially affected FORD MOTOR COMPANY

    Wiring for the power lumbar seat system was routed directly beneath the seat cushion springs and may be abraded by the springs.

    Remedy: Install a fuse within the power lumbar electrical circuit.

    Model years: 1986

  20. Electrical system: wiring

    NHTSA 88V091000 Reported 60,000 vehicles potentially affected FORD MOTOR COMPANY

    Vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.

    Remedy: Installation of a relay with wires of gauge adequate to protect the circuit.

    Model years: 1986, 1987, 1988

  21. Hoses, lines/piping, and fittings (fuel system)

    NHTSA 87V139000 Reported 3,600,000 vehicles potentially affected FORD MOTOR COMPANY

    Spring lock fuel line coupling may not be properly engaged.

    Remedy: Install retainer clips over the couplings to prevent coupling separation and fuel leakage.

    Model years: 1986, 1987

  22. Tank assembly (fuel system)

    NHTSA 86V123000 Reported 107 vehicles potentially affected FORD MOTOR COMPANY

    Fuel tanks may have been scored or penetrated when floor pan mounting holes for the partitions were drilled. Consequence of defect: fuel leakage may occur and in the presence of an ignition source, the potential for a fire would exist.

    Remedy: Replace fuel tanks as necessary.

    Model years: 1986

  23. Leaf spring assembly (suspension)

    NHTSA 86V006000 Reported 38,947 vehicles potentially affected FORD MOTOR COMPANY

    There may be inadequate welding in some underbody structural areas, including those at the rear suspension attachments, which may cause it to separate. Consequence of defect: if rear suspension attachments should separate from the underbody during vehicle use, the axle could shift during acceleration or braking and may adversely affect…

    Remedy: Reinforce suspect weld locations and modify to prevent weld failure.

    Model years: 1986

Other Ford models

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.