FaultScore report
Owners have filed 282 complaints about the 1991 Ford Aerostar with NHTSA between 1995 and 2017. The largest single group is the electrical system.
282
Complaints
28
Crashes reported
78
Fires reported
18
Injuries reported
1 complaint reports a death.
Click any bar to open that year's report.
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
3 crashes, 0 fires
0 crashes, 2 fires
1 crashes, 0 fires
0 crashes, 2 fires
Median failure at 105,410 miles
1 crashes, 0 fires
NHTSA files every complaint against a named sub-assembly, not just a system. This is the difference between knowing it was "the engine" and knowing which part of it — the list to hand a mechanic.
A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.
An investigation is the step before a recall: the agency has seen enough complaints to look into a pattern itself. An open one means it thinks something may be wrong and nothing has been fixed yet.
TRANSFER CASES AND REAR DRIVE SHAFT
PARKING PAWL
WHEN THE AUTOMATIC SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARKING PAWL DOES NOT ALWAYS ENGAGE THE PARK GEAR.THIS CAN LEAD TO THE VEHICLE JUMPING OUT OF GEAR UNINTENTIONALLY AND CAUSE THE VEHICLE TO START ROLLING INADVERTENTLY
A complaint is one owner's allegation. A recall is the point at which the manufacturer or a regulator agreed the defect is real and dangerous enough to fix for free — however old the car is.
Canada runs its own recall programme, and its campaigns do not always mirror the American ones.
Other
Certain vehicles, from Ontario to Newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicle is being driven, the spare tire could drop down, potentially creating a roadway obstacle. Correction: Owners are to inspect the cable, and if corrosion or broken wire strands are present the vehicle is to be taken to a dealer for replacement of the winch assembly. Program ends September 30, 2003.
Electrical
A SHORT CIRCUIT COULD DEVELOP IN THE IGNITION SWITCH THAT COULD LEAD TO OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN OF THE VEHICLE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS IN USE OR UNATTENDED. CORRECTION: IGNITION SWITCH WILL BE REPLACED WITH A REVISED DESIGN SWITCH.
Lights And Instruments
NOTE: ALSO INCLUDES SOME MEDIUM AND HEAVY TRUCKS. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 108 - LIGHTING. DAYTIME RUNNING LIGHT MODULE MAY MALFUNCTION WHICH CAN RESULT IN DAYTIME RUNNING LIGHTS THAT DIM, FLICKER OR GO OFF OR IN SOME INSTANCES MAY REMAIN ON AFTER THE IGNITION IS TURNED OFF. CORRECTION: DAYTIME RUNNING LIGHT MODULE WILL BE REPLACED ON AFFECTED VEHICLES.
Emissions
NOTE: TEMPO/TOPAZ WITH 2.3 LITRE ENGINE AND AEROSTAR WITH 3.0 LITRE ENGINE. THESE VEHICLES SO NOT COMPLY WITH C.M.V.S.S. 1103 - EXHAUST EMISSIONS. DEFECTIVE THROTTLE POSITION SENSORS CAN WEAR OUT PREMATURELY CAUSING AN INTERRUPTION OF THE SENSOR SIGNAL AND ILLUMINATION OF THE MALFUNCTION INDICATOR LIGHT. CORRECTION: THROTTLE POSITION SENSOR WILL BE INSPECTED AND REPLACED IF NECESSARY.
Powertrain
THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHICLE MAY ROLL AS IF IN NEUTRAL IF THE PARKING BRAKE IS NOT SET. THIS COULD RESULT IN A VEHICLE ACCIDENT OR PERSONAL INJURY. CORRECTION: OWNERS WILL BE NOTIFIED OF CONDITION AND ADVISED TO SET THE PARKING BRAKE EACH TIME THEY PARK THEIR VEHICLE. OWNERS WILL ALSO BE ADVISED WHEN DEALERS RECEIVE PARTS AND REPAIR INSTRUCTIONS AFTER FURTHER INVESTIGATION BY FORD.
Recalls cover specific build ranges, so check your own vehicle by VIN at nhtsa.gov/recalls or, in Canada, Transport Canada.
Reports where the owner recorded a crash, a fire, an injury or a death.
ELECTRICAL SYSTEM:IGNITION:SWITCH
I OWNED A 1991 FORD AEROSTAR WHICH BURST INTO FLAMES AND WAS DESTROYED. I HAVE BEEN BOUNCED AROUND TRYING TO GET SATISFACTIONS BUT SINCE THERE WAS AN ONGOING CLASS ACTION LAW SUIT HAVE NOT RECEIVED ANY COMPENSATION. THE CONSUMERS WIFE NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER, RAN TO CALL THE FIRE DEPARTMENT, BUT BY THE TIME HE RETURNED THE VEHICLE WAS FULLY ENGULFED IN FLAMES. UPDATED 04/14/10.
NHTSA complaint #10120979 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION
WHILE DRIVING 65 MPH ANOTHER MOTORIST YELLED AT THE CONSUMER THAT THE VAN WAS ON FIRE. THE FIRE APPEARED TO BE COMING FORM THE MIDDLE TO THE REAR. CONSUMER PULLED OVER, AND NOTICED TRANSMISSION FLUID ON THE UNDERSIDE OF THE VAN. CONSUMER SHUT THE ENGINE OFF, AND FIRE WENT OUT. A TECHNICIAN EXAMINED THE VAN AND STATED THAT THE TRANSFER CASE NEEDED TO BE REPLACED. NHTSA RECALL CAMPAIGN 99V094000 WAS ISSUED.
NHTSA complaint #10073700 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM
CONSUMER STATES THAT WHILE DRIVING DOWN HIGHWAY THE REAR BRAKES LOCKED AND CAUSED A FIRE WHICH MELTED THE REAR TIRES. CONSUMER WAS TRAVELLING APPROX 65MPH WHEN THE VEHICLE BEGAN TO SLOW DOWN AND SMOKE BEGAN COMING FROM THE REAR OF VEHICLE.*JB.
NHTSA complaint #8014819 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE.
NHTSA complaint #762465 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE.
NHTSA complaint #762465 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
FOUR WHEEL DRIVE/TRANSFER CASE BLEW OUT AND CAUGHT ON FIRE.
NHTSA complaint #892227 — an unverified report by a vehicle owner.
In the owners' own words, exactly as filed with NHTSA.
ELECTRICAL SYSTEM
I HAD MY STARTER REPLACED BREAKS AND RELAY AND IT STILL HAVING PROBLEMS WITH THE ELECTRICAL SYSTEM I CANNOT EVEN TURN ON MY HEADLIGHTS
NHTSA complaint #10994317 — an unverified report by a vehicle owner.
UNKNOWN OR OTHER
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS
NHTSA complaint #10151871 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION:SWITCH
I OWNED A 1991 FORD AEROSTAR WHICH BURST INTO FLAMES AND WAS DESTROYED. I HAVE BEEN BOUNCED AROUND TRYING TO GET SATISFACTIONS BUT SINCE THERE WAS AN ONGOING CLASS ACTION LAW SUIT HAVE NOT RECEIVED ANY COMPENSATION. THE CONSUMERS WIFE NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER, RAN TO CALL THE FIRE DEPARTMENT, BUT BY THE TIME HE RETURNED THE VEHICLE WAS FULLY ENGULFED IN FLAMES. UPDATED 04/14/10.
NHTSA complaint #10120979 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
THE FRONT BRAKE ROTORS WARPED, CAUSING THE VEHICLE TO SHIMMY. DEALERSHIP REPAIRED THE PROBLEM TWICE, BUT THE CONSUMER WAS STILL HAVING THE SAME PROBLEMS.
NHTSA complaint #10087370 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION
WHILE DRIVING 65 MPH ANOTHER MOTORIST YELLED AT THE CONSUMER THAT THE VAN WAS ON FIRE. THE FIRE APPEARED TO BE COMING FORM THE MIDDLE TO THE REAR. CONSUMER PULLED OVER, AND NOTICED TRANSMISSION FLUID ON THE UNDERSIDE OF THE VAN. CONSUMER SHUT THE ENGINE OFF, AND FIRE WENT OUT. A TECHNICIAN EXAMINED THE VAN AND STATED THAT THE TRANSFER CASE NEEDED TO BE REPLACED. NHTSA RECALL CAMPAIGN 99V094000 WAS ISSUED.
NHTSA complaint #10073700 — an unverified report by a vehicle owner.
POWER TRAIN
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
NHTSA complaint #10069585 — an unverified report by a vehicle owner.
UNKNOWN OR OTHER
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
NHTSA complaint #10069585 — an unverified report by a vehicle owner.
UNKNOWN OR OTHER
TRANSMISSION FLUID ENTERING COOLANT
NHTSA complaint #10071270 — an unverified report by a vehicle owner.
FUEL SYSTEM, GASOLINE
BRAKES OVERHEAT ON A CURVEY ROAD
NHTSA complaint #10068880 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
NHTSA complaint #10069585 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC
BRAKES OVERHEAT ON A CURVEY ROAD
NHTSA complaint #10068880 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR
PASSENGER SIDE SLIDING DOOR WILL NO LONGER OPEN. VEHICLE HAS NOT BEEN EXAMINED BY DEALER. NLM
NHTSA complaint #8020014 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM
CONSUMER STATES THAT WHILE DRIVING DOWN HIGHWAY THE REAR BRAKES LOCKED AND CAUSED A FIRE WHICH MELTED THE REAR TIRES. CONSUMER WAS TRAVELLING APPROX 65MPH WHEN THE VEHICLE BEGAN TO SLOW DOWN AND SMOKE BEGAN COMING FROM THE REAR OF VEHICLE.*JB.
NHTSA complaint #8014819 — an unverified report by a vehicle owner.
EQUIPMENT:APPLIANCE:AIR CONDITIONER
I WENT TO FIRESTONE IN ST. JOE, MO AND HAD MY AIR CONDITIONING RECHARGED AFTER 9 YEARS OF DRIVING MY VAN. THEY TOLD ME THAT I NEEDED TO REPLACE A HOSE ON THE FRONT OF THE VECHICAL AND THAT THEY NEEDED TO THEN ADD FREON TO THE SYSTEM. THAT WAS IN JULY 19, 2001. IT DIDN'T SEEM AS COLD AS IT HAD BEFORE BUT IT WAS OK. THEN WHEN I NEEDED THE AIR THIS SUMMER I HAD NONE. THEY SAID THAT THE HOSE THAT THEY INSTALLED THEY LATTER WERE TOLD WOULDN'T HOLD THE PRESSURE (I THINK) BUT THAT NOW SENCE IT WAS OVER 6 MONTHS THEY WOULDN'T OR COULDN'T DO ANYTHING. IT COST ME $304.07. THEY SAY THAT YOU PEOPLE KNEW ABOUT THIS PROBLEM. WHAT THE HELL IS GOING ON?
NHTSA complaint #763566 — an unverified report by a vehicle owner.
VEHICLE SPEED CONTROL
AS SOON AS CONSUMER SHIFTED TO DRIVE, VEHICLE ACCELERATED ON ITS OWN, WITH TIRES SPINNING. CONSUMER APPLIED BRAKES, THEN PARK BRAKE, AND SHIFTED TO NEUTRAL. CONSUMER ACCIDENTLY SHIFTED TO REVERSE AND HEARD A LOUD CLUNKING SOUND, VEHICLE CAME TO A STOP.*AK
NHTSA complaint #8011448 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE.
NHTSA complaint #762465 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE.
NHTSA complaint #762465 — an unverified report by a vehicle owner.
EXTERIOR LIGHTING:HEADLIGHTS:SWITCH
I HAVE BEEN DRIVING AT NIGHT ON SEVERAL DIFFERENT OCCASIONS AND HAD THE HEADLIGHTS SUDDENLY GO OUT ON ME. THE SWITCH FOR THE LIGHTS SEEMS TO BE WARM AT THESE TIMES. THE HEATER SEEMS TO CAUSE THE SWITCH TO HEAT UP AND WHEN IT GETS HOT THE LIGHTS GO OFF. IT MAY CAUSE AN ACCIDENT ONE OF THESE TIMES IF IT ISN'T FIXED. I'M NOT SURE IF REPLACING THE SWITCH WILL HELP OR IF IT WILL HAPPEN EVEN WITH A NEW SWITCH BEACUSE OF THE HEAT PROBLEM. MAYBE THE DESIGN OF WHERE THE SWITCH IS IS BAD. PLEASE ADVISE ME ON WHAT TO DO. THANK YOU.
NHTSA complaint #755995 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSION REFUSES TO SHIFT INTO REVERSE OR FORWARD AT TIMES. THE CONSUMER STATED THAT THE TRANSMISSION WAS REBUILT AT 68,000 BY THE DEALER AND WITHIN A FEW MONTHS THE SAME PROBLEMS STARTED UP AGAIN.
NHTSA complaint #899966 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSION REFUSES TO SHIFT INTO REVERSE OR FORWARD AT TIMES. THE CONSUMER STATED THAT THE TRANSMISSION WAS REBUILT AT 68,000 BY THE DEALER AND WITHIN A FEW MONTHS THE SAME PROBLEMS STARTED UP AGAIN.
NHTSA complaint #899966 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION.
NHTSA complaint #899347 — an unverified report by a vehicle owner.
STRUCTURE:BODY:TAILGATE:HINGE AND ATTACHMENTS
THE REAR LIFT SPRING ON THE REAR LIFTGATE BROKE AT THE UP POSISTION WHILE UNLOADING,CAUSING THE DOOR TO COME SLAMING DOWN ON MY BACK.
NHTSA complaint #753220 — an unverified report by a vehicle owner.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
FOUR WHEEL DRIVE/TRANSFER CASE BLEW OUT AND CAUGHT ON FIRE.
NHTSA complaint #892227 — an unverified report by a vehicle owner.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
WHILE DRIVING THE BRAKES FAILED RESULTING IN VEHICLE COLLISION WITH THREE INJURIES, UPON EXPECTION OF THE BRAKE PEDAL TRAVEL AND RESERVOIR (OSHP UNITS 977), NO PRESSURE ON THE PEDAL AND NO FLUID IN THE RESERVOIR (OHIO TRAFFIC CRASH REPORT) *MJS
NHTSA complaint #561545 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
THIS VEHICLE WAS DRIVEN FOR 20 MINUTES WHEN A STRONG ODOR OF PLASTIC BURNING WAS SMELLED. THIS VEHICLE WAS PARKED WHEN WHITE SMOKE WAS NOTICED COMING OUT FROM UNDER THE HOOD. A FEW SECONDS PASSED WHEN THE VEHICLE CAUGHT FIRE AND WAS TOTALLY INVOLVED. THIS VEHICLE WAS TOTALED.
NHTSA complaint #747438 — an unverified report by a vehicle owner.