1991 Ford Aerostar Problems
Owner-reported complaints filed with NHTSA, grouped by component
Data refreshed
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
- Electrical6325.1%
- Transmission4317.1%
- Brakes3513.9%
- Driver assistance239.2%
- Interior & seats156.0%
- Engine135.2%
- Body & structure93.6%
- Steering72.8%
- Powertrain (other)72.8%
- Visibility62.4%
- Other / unspecified52.0%
- Suspension52.0%
- Tires & wheels41.6%
- Fuel system41.6%
- Seat belts20.8%
- Exterior lighting20.8%
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.
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
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
Transmission
Reports naming the automatic or manual transmission, including shifting behaviour, shudder, slipping and transmission control modules.
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
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
Brakes
Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake.
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
BRAKES OVERHEAT ON A CURVEY ROAD
Driver assistance
Reports naming forward-collision avoidance, lane keeping, back-over prevention, cruise control and related electronic driver-assistance systems.
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
WHILE MAKEING A STOP WITH FOOT DEPRESSING BRAKE PEDAL VEHICLE STARTED IDLING HIGH. PLEASE PROVIDE FURTHER INFORMATION.*AK
Interior & seats
Reports naming seats, latches, locks, linkages and interior fittings.
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%
THIS SEAT HAS NOW FAILED AGAIN. ALMOST LOST CONTROL OF VEHICLE BOTH TIMES. *AK
Engine
Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.
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
WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION. *AK
Body & structure
Reports naming the vehicle structure, frame, body panels, doors, hood and trim.
From owner reports, verbatim
PASSENGER SIDE SLIDING DOOR WILL NO LONGER OPEN. VEHICLE HAS NOT BEEN EXAMINED BY DEALER. NLM
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
Heating & air conditioning
Reports naming the heating, ventilation and air-conditioning system.
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
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.
Steering
Reports naming the steering system — racks, columns, power-steering assist and steering linkage.
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
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
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.
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
NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK
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.
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.
BRAKES FAILED.
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.
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.
SPARE TIRE RACK CABLE RUSTED CAUSING TIRE TO FALL OFF.
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.
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
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.
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.
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
BRIDGESTONE TURANZA TIRES P215 70 R14 EXPERIENCED TREAD SEPARATION, CAUSING DAMAGE TO VEHICLE. *SLC
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.
From owner reports, verbatim
BRAKES OVERHEAT ON A CURVEY ROAD
THE FUEL LINE CONNECTED TO THE FUEL INJECTION CAUSED VEHICLE TO CATCH FIRE.
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.
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
POOR LAP SEAT BELT PERFORMANCE, THE TWO MIDDLE SEAT LAP BELTS ARE LOCKED IN PLACE AND WILL NOT DISENGAGE. *AK
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.
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
VEHICLE WITH SEAL BEAM LIGHT KEEPS GOING OUT FOR NO APPARENT REASON. *AK
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
- NHTSA Office of Defects Investigation — owner-reported complaints and the components recorded on them
Data on this page last refreshed .