FaultScore

1991 Ford Aerostar transmission problems

56 of the 282 complaints about the 1991 Ford Aerostar are about the transmission — 20% of everything reported for this model year.

F

56

Complaints

8

Crashes

3

Fires

2

Injuries

Exactly what failed

Automatic Transmission 21 37.5%
Park/Neutral Start Interlock Switch 18 32.1%
Column Shift 6 10.7%
Driveshaft 5 8.9%
Gear Position Indication (Prndl) 2 3.6%
Power Train 1 1.8%
Manual Transmission 1 1.8%
Axle Assembly 1 1.8%
Transfer Case (4-WHEEL Drive) 1 1.8%

Transmission & Drivetrain across every Ford Aerostar year

1987 15 3.6%
1988 19 4.5%
1989 33 7.8%
1990 37 8.8%
1991 56 13.3%
1992 87 20.7%
1993 75 17.8%
1994 48 11.4%
1995 26 6.2%
1996 14 3.3%
1997 11 2.6%

What owners said

Filed with NHTSA, in their own words.

Davenport, IA Fire

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.

Ramona, CA

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.

Chilliwack BC, AK Crash 1 injured

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.

Chilliwack BC, AK Crash 1 injured

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.

College Place, WA

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.

Braidwood, IL Fire

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.

GWS, CO

POWER TRAIN:DRIVELINE:DRIVESHAFT

NO SUMMARY LISTED FOR ABOVE VEHICLE.

NHTSA complaint #741680 — an unverified report by a vehicle owner.

Oceanside, CA

POWER TRAIN:AUTOMATIC TRANSMISSION

A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP REPLACING WHOLE REAR AXLE ASSEMBLY AND DIFFERENTIAL FROM SALVAGE YARD MYSELF BECAUSE IT WAS MUCH LESS EXPENSIVE THAN WHAT THE REPAIR PLACE WANTED. TRANSMISSION BEGAN SLIPPING DURING ACCELERATION. AFTER A COUPLE DAYS IT QUIT MOVING THE VEHICLE COMPLETELY, AS IF IT WERE IN NEUTRAL. I REPLACED THE TRANSMISSION WITH ONE FROM A SALVAGE YARD SINCE, ONCE AGAIN, IT WAS THE LEAST EXPENSIVE WAY TO GO. THE HEATER CORE RECENTLY BEGAN TO LEAK INSIDE THE VEHICLE AND STEAM UP THE WINDOWS. THE HEATER CORE HAS BEEN CAPPED OFF AND NOT YET REPLACED. FINALLY, JUST TWO DAYS AGO THE ENGINE BEGAN RUNNING VERY ROUGH AND INTERMITTENTLY STALLED. LOOKING UNDER THE HOOD REVEALED THERE WAS NO WATER IN THE RADIATOR. UPON RESERVICING THE RADIATOR AND STARTING THE ENGINE WATER WAS NOTICED POURING OUT OF THE EXHAUST PIPE. I CAN ONLY PRESUME EITHER THE HEAD GASKET HAS FAILED OR THE CYLINDER WALL IS CRACKED PERMITTING THE COOLANT WATER TO ENTER THE COMBUSTION CHAMBER. THE VEHICLE IS CURRENTLY UNDRIVEABLE AND PARKED WHILE MY WIFE AND I TRY TO FIGURE OUT HOW TO AFFORD TO FIX YET ANOTHER PROBLEM WITH THIS PIECE OF TRASH FORD AEROSTAR.

NHTSA complaint #729454 — an unverified report by a vehicle owner.

Aspen, CO

POWER TRAIN:DRIVELINE:DRIVESHAFT

CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD HIM THAT HIS VEHICLE WASN'T ON RECALL.

NHTSA complaint #868915 — an unverified report by a vehicle owner.

Aspen, CO

POWER TRAIN:AUTOMATIC TRANSMISSION

CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD HIM THAT HIS VEHICLE WASN'T ON RECALL.

NHTSA complaint #868915 — an unverified report by a vehicle owner.

Aspen, CO

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD HIM THAT HIS VEHICLE WASN'T ON RECALL.

NHTSA complaint #868915 — an unverified report by a vehicle owner.

Aptos, CA

POWER TRAIN:AUTOMATIC TRANSMISSION

VIBRATION PROBLEMS HAVE BEEN CONSISTENT SINCE DATE OF PURCHASE. OTHER OWNERS REPORTED VIBRATION PROBLEMS AND DRIVELINES WERE NOTED AS DEFECTIVE. NONE OF THE CORRECTIONS BY FORD SERVICE CORRECTED THE PROBLEMS IN MY AEROSTAR. RECENT VISITS TO FORD RESULTED IN A SELF DIAGNOSED TRANSFER CASE OUTPUT SHAFT PLAY, CONFIRMED BY MECHANICS AS POSSIBLE CAUSE FOR INCREASINGLY NOTICABLE DRIVE TRAIN VIBRATIONS. CHECK BY SERVICE REPRESENTATIVE REVEALED SAFETY RECALLS (97S83 & 99S13) FOR 1992-1997 FOR AWD AEROSTARS. THE DEALER, FORD AREA REP AND FORD CUSTOMER SERVICE REFUSE TO PERFORM RECOMMENDED SERVICE ACTION FOR MY AEROSTAR AT THEIR EXPENSE CLAIMING THAT THE RECALLS WERE BY VIN # AND MY VEHICLE WAS NOT INCLUDED. FORD HAS ISSUED OVER 170 RECALLS AND SERVICE BULLETINS ON MY VEHICLE BUT ONLY ONE WAS SENT TO ME AND I HAD THE WORK DONE. FORD SHOULD INCLUDE MY VEHICLE IN THE RECALL AND REPLACE ALL DRIVELINE PARTS THAT HAVE BEEN DAMAGED DUE TO THEIR FAILURE TO CORRECTLY PERFORM RECALLED REPAIRS.

NHTSA complaint #722007 — an unverified report by a vehicle owner.

Aptos, CA

POWER TRAIN:DRIVELINE:DRIVESHAFT

VIBRATION PROBLEMS HAVE BEEN CONSISTENT SINCE DATE OF PURCHASE. OTHER OWNERS REPORTED VIBRATION PROBLEMS AND DRIVELINES WERE NOTED AS DEFECTIVE. NONE OF THE CORRECTIONS BY FORD SERVICE CORRECTED THE PROBLEMS IN MY AEROSTAR. RECENT VISITS TO FORD RESULTED IN A SELF DIAGNOSED TRANSFER CASE OUTPUT SHAFT PLAY, CONFIRMED BY MECHANICS AS POSSIBLE CAUSE FOR INCREASINGLY NOTICABLE DRIVE TRAIN VIBRATIONS. CHECK BY SERVICE REPRESENTATIVE REVEALED SAFETY RECALLS (97S83 & 99S13) FOR 1992-1997 FOR AWD AEROSTARS. THE DEALER, FORD AREA REP AND FORD CUSTOMER SERVICE REFUSE TO PERFORM RECOMMENDED SERVICE ACTION FOR MY AEROSTAR AT THEIR EXPENSE CLAIMING THAT THE RECALLS WERE BY VIN # AND MY VEHICLE WAS NOT INCLUDED. FORD HAS ISSUED OVER 170 RECALLS AND SERVICE BULLETINS ON MY VEHICLE BUT ONLY ONE WAS SENT TO ME AND I HAD THE WORK DONE. FORD SHOULD INCLUDE MY VEHICLE IN THE RECALL AND REPLACE ALL DRIVELINE PARTS THAT HAVE BEEN DAMAGED DUE TO THEIR FAILURE TO CORRECTLY PERFORM RECALLED REPAIRS.

NHTSA complaint #722007 — an unverified report by a vehicle owner.

Loveland, OH

POWER TRAIN:AUTOMATIC TRANSMISSION

THE FRONT SEAL FROM THE TRANSMISSION HAD STARTED LEAKING DOWN ON THE EXHAUST CAUSING ENGINE TO CATCH FIRE.

NHTSA complaint #852543 — an unverified report by a vehicle owner.

Whitewater, CO

POWER TRAIN:DRIVELINE:DRIVESHAFT

DRIVESHAFT WAS TOO HEAVY FOR HIGH SPEED DRIVING , CAUSING VEHICLE VIBRATION. ALSO, RUENING SEALS/TRANSFER CASE,AND CAUSING OTHER DAMAGE . DEALER AND MANUFACTURER HAVE BEEN NOTIFIED.

NHTSA complaint #842742 — an unverified report by a vehicle owner.

Pacific, MO

POWER TRAIN:AUTOMATIC TRANSMISSION

CONSUMER DRIVING DOWN ROAD AND WAS GOING FORWARD, AND COULD NOT ENGAGE TO PARK DUE TO TRANSMISSION PROBLEMS.

NHTSA complaint #841958 — an unverified report by a vehicle owner.

Columbia Fall, MT

POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

VEHICLE EXPRIENCE PROBLEM WITH TRANSFER CASE FAILURE WHILE DRIVING ON HIGHWAY AT 80 MPH. CONSUMER LEARN OF A MFR. RECALL ON 1992 VEHICLE CONCERNING TRANSFER CASE/DRIVE SHAFT. SEEKING HELP FROM NHTSA IN THIS MATTER.

NHTSA complaint #840423 — an unverified report by a vehicle owner.

Waxhaw, NC

POWER TRAIN:AUTOMATIC TRANSMISSION

THE SNAP RINGS IN THE AUTOMATIC TRANSMISSION BROKE, CAUSING THE PARTS IN THE TRANSMISSION TO BREAK AND MAY CAUSE AN UNEXPECTED LOSS OF VEHICLE CONTROL REPLACED TRANSMISSION TWICE. DEALER CANNOT DETERMINE THE PROBLEM. PLEASE PROVIDE FURTHER INFORMATION.

NHTSA complaint #834135 — an unverified report by a vehicle owner.

Hagerstown, MD

POWER TRAIN:AXLE ASSEMBLY

STRESS FRACTURES IN THE TRANSAXLES.

NHTSA complaint #526403 — an unverified report by a vehicle owner.

Union City, CA

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

WHILE DRIVING THE VEHICLE STARTED TO SEVERLY VIBRATE,AND WHEN PULLED OVER THERE WAS OIL ALL OVER. TOWED VEHICLE TO FORD DEALER. DEALER REPAIRED VEHICLE, AND STATED THE TRANSFER CASE WAS DESTROYED AND COULD NOT BE REPLACED.

NHTSA complaint #831277 — an unverified report by a vehicle owner.

Hamilton, MT

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

WHILE DRIVING THE TRANSFER CASE AND TRANSMISSION VIBRATE AND BECOME DETACHED AT HIGHWAY SPEEDS. THE MANUFACTURER HAS BEEN NOTIFIED.

NHTSA complaint #826866 — an unverified report by a vehicle owner.

Hamilton, MT

POWER TRAIN:AUTOMATIC TRANSMISSION

WHILE DRIVING THE TRANSFER CASE AND TRANSMISSION VIBRATE AND BECOME DETACHED AT HIGHWAY SPEEDS. THE MANUFACTURER HAS BEEN NOTIFIED.

NHTSA complaint #826866 — an unverified report by a vehicle owner.

Hamilton, MT

POWER TRAIN:MANUAL TRANSMISSION

DEFECTIVE DRIVE SHAFT/TRANSFER CASE CAUSED EXCESSIVE VIBRATION TO THE DRIVE LINE. THIS HAS CAUSED DISRUPTION OF SEALS, CRACKING OF CASINGS, SEPARATION OF COMPONENTS, AND LEAKAGE OF TRANSMISSION FLUID ONTO THE EXHAUST SYSTEM. THE FAILURES ARE FIRST NOTICED BY SMOKE ESCAPING FROMUNDERNEATH THE VEHICLE AND SUDDEN LOSS OF TRANSMISSION FUNCTION.

NHTSA complaint #540008 — an unverified report by a vehicle owner.

Plano, TX Crash

POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH

THE NEUTRAL SAFETY KIT MALFUNCTIONED, CAUSING THE KEYS TO BE REMOVED AT ANY NEUTRAL/ DRIVE ETC. POSITION WHICH CAUSED A ROLLOVER AND ACCIDENT. PLEASE PROVIDE DETAILS.

NHTSA complaint #826412 — an unverified report by a vehicle owner.

Bible School Park, NY

POWER TRAIN:DRIVELINE:DRIVESHAFT

WHILE DRIVING THE DRIVESHAFT BROKE, CAUSE UNKNOWN. PLEASE GIVE ANY FURTHER DETAILS.

NHTSA complaint #822315 — an unverified report by a vehicle owner.

Voorhees, NJ

POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION FAILED SEVERAL TIMES, RECALLS ON OTHER MODELS HOWEVER CONSUMERS VEHICLE DOES NOT MEET REQUIREMENTS FOR RECALL REPAIRS.

NHTSA complaint #528366 — an unverified report by a vehicle owner.

Metarie, LA Crash

POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH

CONSUMER PARKED VEHICLE IN THE GARAGE, GOT OUT AND TOOK THE KEY OUT OF THE IGNITION. ACCIDENTLY, LEFT THE GEAR IN REVERSE. CONSUMER THEN LEANED AGAINST THE VEHICLE AND IT BEGAN ROLLING BACKWARDS. THE VEHICLE HIT THE SIDE OF THE CARPORT AND STOPPED. CONSUMER CONTACTED THE DEALER AND WAS TOLD THAT'S HOW THE VEHICLE WAS DESIGNED.

NHTSA complaint #814621 — an unverified report by a vehicle owner.

Whittier, CA

POWER TRAIN:AUTOMATIC TRANSMISSION

TRANSMISSION FAILED.

NHTSA complaint #519494 — an unverified report by a vehicle owner.

Panama City, FL Fire

POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH

VEHICLE WAS IN THE PARK POSITION FOR 15 TO 20 MIN WHEN THE VEHICLE CAUGHT ON FIRE IN THE WIRING HARNESS AND THE IGNITION SWITCH. CONSUMER STATED THE RECALL WAS CORRECTED. FIRE DEPARTMENT DETERMINED THE FIRE AS AN ELECTRICAL FIRE.*AK CONSUMER TURNED THE VEHICLE OFF REMOVED THE KEY WHICH MEANT THE GEAR SHIFTER SHOULD HAVE BEEN LOCKED IN PARK. THE CONSUMER SON MOVED THE GEAR SHIFT OUT OF PARK AND IT ROLLED INTO OTHER VEHICLE.

NHTSA complaint #813073 — an unverified report by a vehicle owner.

Columbia, MD

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

TRANSMISSION/TRANSFER CASE FAILURE.

NHTSA complaint #512134 — an unverified report by a vehicle owner.

Other 1991 Ford Aerostar problems

← Full 1991 Ford Aerostar report