RoadVitals

1991 Ford Aerostar Problems

Owner-reported complaints filed with NHTSA, grouped by component

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
Components namedHow many of our component categories appear on at least one report for this model year. One report can name several.
17
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

What this page shows

Everything below is an owner-reported complaint submitted to NHTSA about the 1991 Ford Aerostar, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.

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

Reports by component

Ranked by how many owner reports name each component category

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

Each component in detail

What the reports in each category say, in the owners' own words

Electrical

Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.

63
reports

From owner reports, verbatim

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 · filed Jun 11, 2017

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 · filed May 16, 2005
All 63 reports naming electrical

Transmission

Reports naming the automatic or manual transmission, including shifting behaviour, shudder, slipping and transmission control modules.

43
reports

From owner reports, verbatim

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 May 17, 2004

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. *AK

NHTSA ID 762465 · filed May 30, 2002
All 43 reports naming transmission

Brakes

Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake.

35
reports

From owner reports, verbatim

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 · filed Aug 6, 2004

BRAKES OVERHEAT ON A CURVEY ROAD

NHTSA ID 10068880 · filed Jan 15, 2004
All 35 reports naming brakes

Driver assistance

Reports naming forward-collision avoidance, lane keeping, back-over prevention, cruise control and related electronic driver-assistance systems.

23
reports

From owner reports, verbatim

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 *JB

NHTSA ID 8011448 · filed Jun 11, 2002

WHILE MAKEING A STOP WITH FOOT DEPRESSING BRAKE PEDAL VEHICLE STARTED IDLING HIGH. PLEASE PROVIDE FURTHER INFORMATION.*AK

NHTSA ID 889456 · filed May 31, 2001
All 23 reports naming driver assistance

Interior & seats

Reports naming seats, latches, locks, linkages and interior fittings.

15
reports

From owner reports, verbatim

THE REAR HATCHBACK FREEZES (LOCKED) CLOSED AND I AM NOT ABLE TO OPEN FROM EITHER SIDE. WHICH COULD PROVE DANGEROUS IN A CRASH SITUATION. THIS IS MY SECOND AEROSTAR WITH THE SAME PROBLEM. THE USEFULNESS OF THE VIHICAL IS CUT BY MORE THAN 75%

NHTSA ID 743268 · filed Mar 29, 2001

THIS SEAT HAS NOW FAILED AGAIN. ALMOST LOST CONTROL OF VEHICLE BOTH TIMES. *AK

NHTSA ID 740662 · filed Feb 9, 2001
All 15 reports naming interior & seats

Engine

Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.

13
reports

From owner reports, verbatim

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 · filed Jan 15, 2004

WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION. *AK

NHTSA ID 899347 · filed Nov 21, 2001
All 13 reports naming engine

Body & structure

Reports naming the vehicle structure, frame, body panels, doors, hood and trim.

9
reports

From owner reports, verbatim

PASSENGER SIDE SLIDING DOOR WILL NO LONGER OPEN. VEHICLE HAS NOT BEEN EXAMINED BY DEALER. NLM

NHTSA ID 8020014 · filed Oct 2, 2002

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. *AK

NHTSA ID 753220 · filed Oct 14, 2001
All 9 reports naming body & structure

Heating & air conditioning

Reports naming the heating, ventilation and air-conditioning system.

8
reports

From owner reports, verbatim

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?*AK

NHTSA ID 763566 · filed Jun 27, 2002

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 ID 729454 · filed Aug 29, 2000
All 8 reports naming heating & air conditioning

Steering

Reports naming the steering system — racks, columns, power-steering assist and steering linkage.

7
reports

From owner reports, verbatim

WHILE VEHICLE WAS DRIVEN BY THE OWNER'S WIFE THE VEHICLE CAUGHT ON FIRE FROM TOP TO BOTTOM. ACCORDING TO OWNER, THE FIRE STARTED INSIDE OF THE VEHICLE AROUND THE STEERING COLUMN, COSTING THE LIFE OF THE DRIVER AT THE TIME. *AK

NHTSA ID 817992 · filed Dec 15, 1997

IGNITION SWITCH KEY CAN BE REMOVED WHEN TRANSMISSION IS IN DRIVE POSITION, NOT CHECKED BY DEALER. *AK CONSUMER STATED VEHICLE WILL ROLL, UNLESS PARKING BRAKE IS APPLIED POWER STEERING AND BRAKES DO NOT FUNCTION PROPERLY.*JB

NHTSA ID 813292 · filed Jun 19, 1997

Too few reports in this category for a page of its own — they appear in the full complaint list.

Powertrain (other)

Powertrain reports that are not specifically the engine or transmission — driveshafts, axles, transfer cases and differentials.

7
reports

From owner reports, verbatim

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 · filed Jan 15, 2004

NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK

NHTSA ID 741680 · filed Feb 28, 2001

Too few reports in this category for a page of its own — they appear in the full complaint list.

Visibility

Reports naming windshields, glass, wipers, defrosters and mirrors.

6
reports

From owner reports, verbatim

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 ID 729454 · filed Aug 29, 2000

BRAKES FAILED.

NHTSA ID 519494 · filed Jul 16, 1997

Too few reports in this category for a page of its own — they appear in the full complaint list.

Other / unspecified

Reports whose component NHTSA recorded as unknown, or that do not map to one of the categories above.

5
reports

From owner reports, verbatim

SPARE TIRE LOCATED UNDER REAR OF VEHICLE IS HELD UP BY A CABLE. THE CABLE BROKE WHILE SITTING IN THE DRIVEWAY. THE SPARE TIRE FELL TO THE GROUND. I HATE TO THINK WHAT WOULD HAVE HAPPENED IF I WAS DRIVING 65MPH WHEN IT FELL. DEALER DID NOT SEEM INTERESTED.

NHTSA ID 703673 · filed Feb 23, 1999

SPARE TIRE RACK CABLE RUSTED CAUSING TIRE TO FALL OFF.

NHTSA ID 604703 · filed Jun 24, 1998

Too few reports in this category for a page of its own — they appear in the full complaint list.

Suspension

Reports naming suspension components — springs, struts, shocks, control arms and related hardware.

5
reports

From owner reports, verbatim

ONGOING PROBLEM WITH SEVERE VIBRATION WHILE TRAVELING AT 50 MPH. VEHICLE BEEN IN DEALER SHOP ON SEVERAL OCCASIONS, BUT PROBLEM STILL OCCURS. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK

NHTSA ID 875109 · filed Nov 16, 2000

DRIVER HEARD A LOUD POPPING NOISE FROM THE FRONT END AND THE VEHICLE COLLAPSED BY KNEELING TO THE LEFT. THE SUSPENSION AND WHEEL ASSEMBLY DISCONNECTED FROM THE SUPPORT BRACKET BECAUSE TWO SUPPORT PINS OR RIVETS HAD SHEARED OFF.

NHTSA ID 536860 · filed Jun 14, 1998

Too few reports in this category for a page of its own — they appear in the full complaint list.

Tires & wheels

Reports naming tires, wheels, hubs, or the tire-pressure monitoring system.

4
reports

From owner reports, verbatim

PE00 202; CONSUMER WAS TRAVELING 60MPH ON HIGHWAY AND HEARD A POPPING NOISE, WAS ABLE TO PULL VEHICLE OVER. HE NOTICED THAT RIGHT REAR TIRE TREAD SEPARATED AND AIR WAS STILL INSIDE OF TIRE. FIRESTONE TIRE #P23575R15. THERE WERE NO INJURIES.*AK TREAD SEPARATION CAUSED DAMAGE TO VEHICLE. *SLC

NHTSA ID 883853 · filed Mar 22, 2001

BRIDGESTONE TURANZA TIRES P215 70 R14 EXPERIENCED TREAD SEPARATION, CAUSING DAMAGE TO VEHICLE. *SLC

NHTSA ID 555778 · filed Oct 12, 2000

Too few reports in this category for a page of its own — they appear in the full complaint list.

Fuel system

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.

4
reports

From owner reports, verbatim

BRAKES OVERHEAT ON A CURVEY ROAD

NHTSA ID 10068880 · filed Jan 15, 2004

THE FUEL LINE CONNECTED TO THE FUEL INJECTION CAUSED VEHICLE TO CATCH FIRE.

NHTSA ID 780620 · filed Oct 1, 1998

Too few reports in this category for a page of its own — they appear in the full complaint list.

Seat belts

Reports naming seat belts, buckles, retractors and pretensioners.

2
reports

From owner reports, verbatim

CONSUMER HAD BOUGHT A VEHICLE WITHOUT SEAT BELTS. DEALER REFUSED TO INSTALL SEAT BELTS. CONSUMER NEEDS THEM FOR CHILDREN SAFETY.*AK *SLC

NHTSA ID 882352 · filed Mar 7, 2001

POOR LAP SEAT BELT PERFORMANCE, THE TWO MIDDLE SEAT LAP BELTS ARE LOCKED IN PLACE AND WILL NOT DISENGAGE. *AK

NHTSA ID 804177 · filed Oct 28, 1996

Too few reports in this category for a page of its own — they appear in the full complaint list.

Exterior lighting

Reports naming headlights, tail lights, turn signals and other exterior lighting.

2
reports

From owner reports, verbatim

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.*AK

NHTSA ID 755995 · filed Dec 24, 2001

VEHICLE WITH SEAL BEAM LIGHT KEEPS GOING OUT FOR NO APPARENT REASON. *AK

NHTSA ID 980378 · filed Mar 7, 1996

Too few reports in this category for a page of its own — they appear in the full complaint list.

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.

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .