RoadVitals

1991 Ford Aerostar

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
223
Latest Jun 11, 2017
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
4
Latest Apr 8, 1998
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
2
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
93
25 injuries, 1 deaths reported

Overview

Our database contains 223 NHTSA owner-reported complaints for the 1991 Ford Aerostar, most frequently naming the electrical, transmission and brakes categories. 4 safety recalls have been issued covering this model year; 2 NHTSA investigations name it; and 48 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

4 campaigns cover this model year

View all 4

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
98E010000

SERVICE BRAKES, AIR:DISC:ROTOR

Apr 8, 1998
23,500 units potentially affected
The defect: EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
The risk: LOSS OF BRAKING CAN RESULT.
The remedy: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
AIMCO PRODUCTS INC.View on NHTSA.gov
96V071000

ELECTRICAL SYSTEM:IGNITION

Apr 25, 1996
7,900,000 units potentially affected
The defect: THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
The risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
The remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.
FORD MOTOR COMPANYView on NHTSA.gov
91V189000

POWER TRAIN:AUTOMATIC TRANSMISSION

Nov 4, 1991
792,000 units potentially affected
The defect: WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
The risk: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VEHICLE ACCIDENT.
The remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
FORD MOTOR COMPANYView on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

EA99002ClosedEngineering Analysis

TRANSFER CASES AND REAR DRIVE SHAFT

Opened Jan 7, 1999
Closed Nov 14, 2000

There is no summary currently available

POWER TRAINLed to recall 99V094000
RQ97015ClosedRecall Query

PARKING PAWL

Opened Oct 29, 1997
Closed Apr 1, 1999

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

POWER TRAIN:AUTOMATIC TRANSMISSIONLed to recall 91V189000

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 223
Electrical
Filed Jun 11, 2017

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 ID
10994317
Incident
May 9, 2017
Filed Feb 21, 2006

CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM

NHTSA ID
10151871
Incident
Jan 1, 1901
Electrical
Filed May 16, 2005
Fire reported

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.*JB

NHTSA ID
10120979
Incident
Aug 27, 1996
Brakes
Filed Aug 6, 2004

THE FRONT BRAKE ROTORS WARPED, CAUSING THE VEHICLE TO SHIMMY. DEALERSHIP REPAIRED THE PROBLEM TWICE, BUT THE CONSUMER WAS STILL HAVING THE SAME PROBLEMS. *AK

NHTSA ID
10087370
Incident
Jan 8, 2004
Mileage
150,000 mi
Transmission
Filed May 17, 2004
Fire reported

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. *AK

NHTSA ID
10073700
Filed Jan 15, 2004

TRANSMISSION FLUID ENTERING COOLANT

NHTSA ID
10071270
Incident
Oct 15, 2003
Mileage
105,410 mi
EnginePowertrain (other)
Filed Jan 15, 2004

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 ID
10069585
Incident
Nov 15, 2002
BrakesFuel system
Filed Jan 15, 2004

BRAKES OVERHEAT ON A CURVEY ROAD

NHTSA ID
10068880
Incident
Aug 15, 2003

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

02142

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT

01197

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT

01156

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC

01157

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC

01124

ENGINE AND ENGINE COOLING:ENGINE

ON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA AFTER AN ENGINE OIL PAN GASKET REPAIR HAS BEEN PERFORMED. *TT

002310

POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Ford Aerostar by model year
YearComplaintsRecallsInvestigationsIssue Index
2000600—
1999700—
1998400—
1997635259.7
19961046260.5
19951577365.5
19942575566.7
19933744566.4
19923175566.5
1991Viewing2234271.0
19901957574.3
19892606975.6
198817751270.9
198711452075.3
19865391775.7
1985002—
1984000—
1976000—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.