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1994 problems

FaultScore report

1994 Ford Aerostar problems

Owners have filed 384 complaints about the 1994 Ford Aerostar with NHTSA between 1995 and 2017. The largest single group is the electrical system. Across this model's run it ranks 2 of 7 worst.

Read the complaints What breaks Worst years for the Ford Aerostar All 1994 cars

FaultScore 80/100

Higher is worse. Measured against the other years of the Ford Aerostar.

How this is worked out

The numbers

384

Complaints

Crashes reported

Fires reported

Injuries reported

4 complaints report a death.

120,000 mi

Median mileage at failure

Half of reported failures happened before this

Failed under 36,000 miles

Inside a typical bumper-to-bumper warranty

What kind of bad

The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.

The dashed ring is 50 — the national norm. Further out is worse.

Complaint volume — 99: Against the median year of the Ford Aerostar. 50 means typical for this model; 100 means roughly double.
Severity — 100: 24.2% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 0: 0% of failures with a mileage on record happened under 36,000 miles, against a national rate of 29%.

How 1994 compares with every other Ford Aerostar

Click any bar to open that year's report.

72 140 230 328 254 282 439 541 384 204 124 83 4 13 11

86 87 88 89 90 91 92 93 94 95 96 97 98 99 00

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks on a 1994 Ford Aerostar

Every complaint is filed against a part. Follow any row for the complaints about that part alone.

Electrical System 79 20.6%

0 crashes, 20 fires · median 120,000 mi

Transmission & Drivetrain 48 12.5%

0 crashes, 3 fires · median 120,000 mi

Airbags 45 11.7%

17 crashes, 0 fires · median 120,000 mi

Brakes 31 8.1%

2 crashes, 0 fires · median 120,000 mi

Engine & Cooling 25 6.5%

0 crashes, 3 fires · median 100,000 mi

Steering 22 5.7%

2 crashes, 0 fires · median 120,000 mi

Fuel & Propulsion 20 5.2%

1 crashes, 5 fires

Body & Structure 16 4.2%

1 crashes, 1 fires · median 114,544 mi

Lights 13 3.4%

0 crashes, 1 fires · median 120,000 mi

Suspension 13 3.4%

Median failure at 120,000 miles

Seat Belts 12 3.1%

2 crashes, 0 fires · median 100,000 mi

Acceleration & Cruise Control 12 3.1%

1 crashes, 0 fires · median 122,500 mi

Tires 11 2.9%

Windows, Mirrors & Wipers 10 2.6%

Median failure at 105,800 miles

Seats 8 2.1%

2 crashes, 0 fires

Other & Unspecified 7 1.8%

Equipment & Accessories 5 1.3%

Wheels 5 1.3%

Median failure at 120,000 miles

Doors, Latches & Locks 2 0.5%

Exactly what failed

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.

Switch 23 20.7%

Frontal 16 14.4%

Automatic Transmission 15 13.5%

Column Shift 14 12.6%

Horn 12 10.8%

Antilock/Traction Control/Electronic Limited Slip 12 10.8%

Front Underhood 11 9.9%

Steering Wheel/Handle BAR 8 7.2%

When it fails

Odometer readings owners gave when they filed. About half of all complaints include one.

50,000 – 74,999 miles 2 5.4%

75,000 – 99,999 miles 2 5.4%

100,000 – 149,999 miles 32 86.5%

150,000+ miles 1 2.7%

When owners complained

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.

Feb 1995 peak 20 Oct 2017

NHTSA investigations into the 1994 Ford Aerostar

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.

PE02076 Opened 10 Oct 2002 Closed 10 Mar 2003 STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

LUGGAGE COMPARTMENT DOOR DROPS ABRUPTLY

ODI HAS IDENTIFIED 30 INCIDENTS RESULTING IN MINOR TO MODERATE PERSONAL INJURIES THAT HAVE BEEN CAUSED BY ABRUPT DOOR DROPS OVER THE APPROXIMATELY EIGHT - TWELVE YEAR PERIOD OF PRODUCT USAGE AND EXPOSURE (1991-1995 TO 2003).MOST OF THE INJURY INCIDENTS APPEAR TO HAVE BEEN CAUSED BY A FRACTURE OF THE GAS FILLED LIFT ASSIST CYLINDER MOUNTING STUD.STUD FRACTURES HAVE OCCURRED RANDOMLY OVER TIME AND DO NOT EXHIBIT ANY APPARENT TREND RELATING TO DATE OF VEHICLE PRODUCTION OR TIME-IN-SERVICE (EXPOSURE).THE ODI CLOSING REPORT SUMMARIZES THE DETAILS OF THIS INVESTIGATION.

EA99002 Opened 7 Jan 1999 Closed 14 Nov 2000 POWER TRAIN

TRANSFER CASES AND REAR DRIVE SHAFT

RQ98012 Opened 31 Jul 1998 Closed 7 Jan 1999 POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

TRANSFER CASES AND REAR DRIVESHAFT

EA98016 Opened 14 Jul 1998 Closed 12 Feb 1999 VEHICLE SPEED CONTROL:LINKAGES

FUEL SENDER ASSEMBLY FIRES

PE98010 Opened 13 Feb 1998 Closed 14 Jul 1998 VEHICLE SPEED CONTROL:LINKAGES

FUEL SENDER ASSEMBLY FIRES

OWNERS ALLEGE THAT FAILURE OF THE FUEL PUMP/SENDER CONNECTOR RESULTS IN SHORT CIRCUIT THAT HAS RESULTED IN VEHICLE FIRES.SYMPTOMS INCLUDE ERRATIC FUEL GAUGE OPERATION, , SMOKE FROM THE DASH ON THE DRIVER'S SIDE NEAR THE STEERING COLUMN (FUEL PUMP FUSIBLE LINK) AND PASSENGER SIDE (FUEL PUMP INERTIA CUTOFF SWITCH), INTERMITTENT STALL AND NO START CONCERNS, AND A BURNING ODOR. SEVERAL INCIDENTS HAVE RESULTED IN DAMAGE TO PLASTIC FUEL TUBES AND/OR FUEL SUPPLY/RETURN TUBES.

Recalls on the 1994 Ford Aerostar

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 — Transport Canada

Canada runs its own recall programme, and its campaigns do not always mirror the American ones.

Recall 2001193 16 Jul 2001 139,310 units in Canada

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.

Recall 1999032 2 Mar 1999 118,156 units in Canada

Electrical

On certain vehicles, a short circuit could occur at the A2 accessory terminal in the ignition switch of these vehicles when the switch is in the "on" position causing overheating and the potential for a vehicle fire. Correction: A jumper harness with a relay will be installed which will re-route and activate all A2 accessories through the relay.

Recall 1999031 2 Mar 1999 5,400 units in Canada

Electrical

On certain vehicles, a short circuit could cause heat damage, including melting or charring of the wire harness for the fuel pump and sender assembly and associated wire harnesses. In some cases the short circuit could have the potential for a vehicle fire. Correction: A fused jumper harness will be installed in the fuel pump ground circuit at the fuel pump inertia shut-off switch.

Recall 1997207 20 Nov 1997 22,467 units in Canada

Powertrain

On certain Aerostar AWD vehicles, extended operation at speeds of over 130 kph may result in structural failure of the transmission/transfer case assembly. This could result in fluid expulsion, driveshaft separation or loss of vehicle drive. Fluid leakage in the presence of an ignition source could cause a vehicle fire and driveshaft separation may lead to loss of vehicle control. Correction: Transfer case extension housing will be replaced and steel driveshaft will be replaced with an aluminum driveshaft.

Recalls cover specific build ranges, so check your own vehicle by VIN at nhtsa.gov/recalls or, in Canada, Transport Canada.

Complaints that involved harm

Reports where the owner recorded a crash, a fire, an injury or a death.

Filed 12 Aug 2013 at 93,000 miles Norfolk, VA Fire

ELECTRICAL SYSTEM

VAN HAD BEEN DRIVEN FOR APPROXIMATELY TWO HOURS OR SO, AROUND THE LOCAL CITY COMMUNITIES. VAN HAD BEEN PARKED FOR APPROXIMATELY FIVE MINUTES, WHEN NEIGHBORS NOTIFIED ME OF FIRE. INTENSE FIRE WAS COMING FROM DRIVER'S SIDE/WINDSHIELD/IGNITION/FRONT SEAT AREA, EVENTUALLY CONSUMING ENTIRE INTERIOR OF VAN. NORFOLK FIRE DEPARTMENT RESPONDED WITHIN FIVE MINUTES, OR SO, STATION ONLY ABOUT 150 YARDS FROM MY RESIDENCE. FIRE WAS EXTINGUISHED WITHIN FIVE MINUTES OR SO, BUT THE VAN WAS COMPLETELY CONSUMED BY FIRE AND TOTALLY DESTROYED BY THEN. VAN WAS JUNKED/SALVAGED. PAID ONLY $100.00 FOR SALVAGE/JUNK/TOWING, ETC. PRIOR TO THIS INCIDENT, I HAD NO PROBLEMS WITH MY VAN. VAN ONLY HAD 93000 MILES. HAD PURCHASED NEW FROM FREEDOMS FORD IN NORFOLK, VA. INFORMED BY ASSOCIATE THAT I SHOULD REPORT THIS "FIRE HAZARD/PROBLEM," BECAUSE OTHER 1994 FORD AEROSTAR VANS HAVE EXPERIENCED SIMILAR "FIRE PROBLEMS/INCIDENTS/REPORTS," AND THE LIKE. PLEASE INFORM ME OF WHAT ACTIONS I NEED TO TAKE TO RECOUP SOME MONETARY VALUE FOR THIS "FIRE INCIDENT," ETC. MY VEHICLE PAPERWORK WAS BURNED/DESTROYED IN THE FIRE. HOWEVER, THE NORFOLK FIRE DEPARTMENT DID MAKE AN "OFFICIAL FIRE REPORT/RECORD" OF THE INCIDENT, ETC. ALSO, MINOR DAMAGE WAS DONE TO THE ALUMINUM SIDING OF MY HOUSE FROM THE VEHICLE FIRE.

NHTSA complaint #10534938 — an unverified report by a vehicle owner.

Filed 6 Feb 2008 at 110,000 miles Placentia, CA Fire

ELECTRICAL SYSTEM:IGNITION

CAR WAS PARKED IN DRIVEWAY, UNTOUCHED, FOR AT LEAST 24 HOURS. FIRE ERUPTED ABOUT 7:00 AM. FLAMES WERE COMING THROUGH THE DRIVERS SIDE WINDSHIELD. SEEMED TO BE ELECTRICAL IN NATURE. CAR IS A TOTAL LOSS. CAR IS COMPLETELY ORIGINAL (NO ELECTRIC ALTERATIONS). CAR HAD BEEN TO THE DEALER WITHIN THE LAST 2 YEARS SO ANY RECALL WORK SHOULD HAVE BEEN DONE.

NHTSA complaint #10217101 — an unverified report by a vehicle owner.

Filed 11 Aug 2005 at 100,000 miles Bloomington, CA Fire

ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

DT: THE CONTACT STATED 1994, FORD VAN CAUGHT ON FIRE ON THE FREEWAY ON 8-8-05. SHE WAS NOT HAVING PROBLEMS PRIOR TO THE FIRE. THE FIRE SEEMED TO BE ELECTRICAL AND ORIGINATED UNDER THE HOOD. *AK *JB UPDATED 2/7/2006 - THE CONSUMER RECEIVED RECALL 97V204000 ON NOV 13, 1997 FOR THE TRANSFER CASE/DRIVESHAFT BUT THE DEALER REFUSED TO MAKE THE REPAIRS. THIS FAILURE OF THIS COMPONENT COULD RESULT IN A FIRE. THE CONSUMER RECEIVED INFORMATION FROM NHTSA ON TWO RECALLS FOR THE VEHICLE. ONE WAS 99V028000 FOR THE ELECTRICAL WIRING UNDER THE HOOD AND THE OTHER ONE WAS 99V029000 FOR THE IGNITION SWITCH.

NHTSA complaint #10132510 — an unverified report by a vehicle owner.

Filed 11 Aug 2005 at 100,000 miles Bloomington, CA Fire

ENGINE AND ENGINE COOLING:ENGINE

NHTSA complaint #10132510 — an unverified report by a vehicle owner.

Filed 10 Aug 2004 at 137,000 miles Affton, MO Crash 1 injured

AIR BAGS

CONSUMER'S VEHICLE WAS INVOLVED IN A HEAD ON COLLISION WHILE GOING THROUGH AN INNER SECTION BETWEEN 25-30 MPH. UPON IMPACT, DRIVER'S SIDE AIR BAG FAILED TO DEPLOY. DRIVER SUSTAINED CHEST INJURIES FROM THE SEAT BELT. MANUFACTURER WANTED TO SEND A FACTORY REPRESENTATIVE TO INVESTIGATE THE CAUSE OF THE FAILURE.

NHTSA complaint #10087578 — an unverified report by a vehicle owner.

Filed 25 Jun 2003 at 90,000 miles Riverdale, GA Crash 1 injured

AIR BAGS:FRONTAL

CONSUMER STATES THAT A FRONT COLLISION OCCURRED AND THE AIR BAG DEPLOYED ON HER FACE. SINCE THEM SHE HAD A RESPIRATORY PROBLEM.

NHTSA complaint #10024907 — an unverified report by a vehicle owner.

The most recent complaints

In the owners' own words, exactly as filed with NHTSA.

Filed 25 Oct 2017 Dacula, GA

SEAT BELTS

AIRBAG (CODE 13 AND 51) LIGHTS FLASHING

NHTSA complaint #11039844 — an unverified report by a vehicle owner.

Filed 25 Oct 2017 Dacula, GA

AIR BAGS

AIRBAG (CODE 13 AND 51) LIGHTS FLASHING

NHTSA complaint #11039844 — an unverified report by a vehicle owner.

Filed 12 Aug 2013 at 93,000 miles Norfolk, VA Fire

ELECTRICAL SYSTEM

NHTSA complaint #10534938 — an unverified report by a vehicle owner.

Filed 13 Jun 2012 Hollywood, FL

ELECTRICAL SYSTEM

HAD THE CLOCK RING REPAIRED (YEAR 2000)DUE TO THE AIRBAG LIGHT STAYED ON. NOW THE AIRBAG LIGHT STAYS ON ,THERE IS NO HORN AND THE CRUISE CONTROL DOESNT WORK. THERE HAS TO BE A RECALL FOR THIS SAFETY PROBLEM.

NHTSA complaint #10461633 — an unverified report by a vehicle owner.

Filed 8 Jul 2009 Murrieta, CA

ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

WE WERE BEGINNING TO EXPERIENCE LOSS OF POWER. THE FUEL PUMP AND FILTER WAS CHANGED. WE ARE STILL GETTING INTERMITTENT LOSS OF POWER, BUT WHAT MY CONCERN IS THAT I SAW A RECALL ON NHTSA: 99V028000. I WAS MADE AWARE OF THIS RECALL WHEN I VIEWED AN EPISODE OF COPS WHERE AN AEROSTAR'S ELECTRICAL SYSTEM CAUSED A FIRE IN THE ENGINE COMPARTMENT. I CALLED FORD IN TEMECULA CALIF AND NOW THEY HAVE NO RECORD OF ANY RECALLS FOR THIS YEAR OF AEROSTAR 1994 I DO HAVE KIDS AND I WOULD LIKE TO KNOW WHAT SAFETY MATTERS REMAIN ON THIS VAN.

NHTSA complaint #10276149 — an unverified report by a vehicle owner.

Filed 8 Jul 2009 Murrieta, CA

FUEL SYSTEM, GASOLINE

NHTSA complaint #10276149 — an unverified report by a vehicle owner.

Filed 5 Jul 2008 at 120,000 miles Sioux City, IA

AIR BAGS

ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION.

NHTSA complaint #10233257 — an unverified report by a vehicle owner.

Filed 5 Jul 2008 at 120,000 miles Sioux City, IA

VEHICLE SPEED CONTROL

ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION.

NHTSA complaint #10233257 — an unverified report by a vehicle owner.

Filed 5 Jul 2008 at 120,000 miles Sioux City, IA

ELECTRICAL SYSTEM:HORN

ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION.

NHTSA complaint #10233257 — an unverified report by a vehicle owner.

Filed 5 Jul 2008 at 120,000 miles Sioux City, IA

ELECTRICAL SYSTEM

ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION.

NHTSA complaint #10233257 — an unverified report by a vehicle owner.

Filed 12 Feb 2008 at 120,000 miles Pottstown, PA

SUSPENSION:FRONT

FRONT COIL SPRINGS SNAPPED, HAD TO REPLACED WITH READING SPRING WORKS, THEY HAD TO SEND THE SPECKS TO CHICAGO. MY FORD AERO STAR 4 WHEEL DRIVE & 4.0 V6 IS NOT AVAILABLE FROM AFTER MARKET. THE ONLY OPTION IS TO BUY NEW OR USED FORD SPRINGS WHICH ARE MADE IN CHINA. THE LOCAL FORD DEALER ADMITS REPLACING COIL & LEAF SPRINGS ON SEVERAL MODELS. MIDAS WAS SO BUSY REPLACING FORD SPRINGS, THEY COULD NOT SET UP AN APPOINTMENT TO INSTALL SPRINGS EVEN IF I HAD THE SPRINGS.