Model year record

1991 Ford Aerostar recalls & problems

The 1991 Ford Aerostar has 4 safety recalls and 223 owner complaints on file with NHTSA. The most-reported problem area is electrical system (76 complaints).

Recalls4safety recalls

Complaints223filed by owners

Crashes · fires23 · 69reported in complaints

Injuries · deaths25 · 1reported in complaints

Safety recalls

Service brakes, airApr 8, 1998

Disc › Rotor

Recall 98E01000023,500 vehicles

Problem: 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.
Risk: LOSS OF BRAKING CAN RESULT.
Fix: 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.

Electrical systemApr 25, 1996

Ignition

Recall 96V0710007,900,000 vehiclesopened after NHTSA action (ODI)

Problem: THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
Fix: DEALERS WILL REPLACE THE IGNITION SWITCH.

Power trainNov 4, 1991

Automatic transmission

Recall 91V189000792,000 vehiclesopened after NHTSA action (ODI)

Problem: WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
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.
Fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

Seat beltsSep 20, 1991

Front › Anchorage

Recall 91V1640004,842 vehiclesopened after NHTSA action (OVSC)

Problem: SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Risk: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
Fix: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

Aerostar Van

19mpg combined

City / highway	17 / 22 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $3,550/year to fuel

Aerostar Van

18mpg combined

City / highway	16 / 21 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,700/year to fuel

Aerostar Wagon

18mpg combined

City / highway	16 / 22 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $3,700/year to fuel

Aerostar Van

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,950/year to fuel

Aerostar Wagon

17mpg combined

City / highway	15 / 21 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,950/year to fuel

Aerostar Van AWD

16mpg combined

City / highway	14 / 19 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel

Aerostar Wagon

16mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,200/year to fuel

Aerostar Wagon AWD

16mpg combined

City / highway	14 / 19 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Electrical systemIgnition › Switch; Wiring › Front underhood	76	0	62	0	—
Power trainAutomatic transmission; Automatic transmission › Park/neutral start interlock switch	56	8	3	2	—
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Master cylinder	37	3	1	4	—
Vehicle speed controlAccelerator pedal; Linkages	23	12	0	13	—
EquipmentAppliance › Air conditioner; Mechanical › Carrier/rack	15	0	1	0	—
Engine and engine coolingEngine › Gasoline; Engine	14	0	6	0	—
StructureBody › Door; Body › Hood	10	0	1	6	—
VisibilityPower window devices and controls; Windshield wiper/washer	8	0	0	0	—
Latches/locks/linkagesHatchback/liftgate › Lock; Doors › Latch	7	3	0	4	—
SteeringSteering wheel/handle bar; Linkages › Tie rod assembly	7	0	2	0	—
SuspensionRear; Front › Springs › Air suspension › Springs/bags	5	1	0	0	—
TiresTread/belt; Temporary/emergency spare tire	4	0	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Electrical system
I HAD MY STARTER REPLACED BREAKS AND RELAY AND IT STILL HAVING PROBLEMS WITH THE ELECTRICAL SYSTEM I CANNOT EVEN TURN ON MY HEADLIGHTS
May 9, 2017
Unknown or other
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM
Jan 1, 1901
Electrical system › Ignition › SwitchFire
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
Aug 27, 1996
Service brakes, hydraulic › Foundation components › Disc › Rotor
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
Jan 8, 2004 · 150,000 miles
Power train › Automatic transmissionFire
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
May 17, 2004
Unknown or other
TRANSMISSION FLUID ENTERING COOLANT
Oct 15, 2003 · 105,410 miles
Unknown or other
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
Nov 15, 2002
Service brakes, hydraulic
BRAKES OVERHEAT ON A CURVEY ROAD
Aug 15, 2003

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

TRANSFER CASES AND REAR DRIVE SHAFTClosedLed to recall 99V094000
There is no summary currently available
EA99002 · opened Jan 7, 1999 · closed Nov 14, 2000
PARKING PAWLClosedLed to recall 91V189000
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
RQ97015 · opened Oct 29, 1997 · closed Apr 1, 1999