Model year record

1992 Ford Aerostar recalls & problems

The 1992 Ford Aerostar has 5 safety recalls and 317 owner complaints on file with NHTSA. The most-reported problem area is power train (87 complaints).

Recalls5safety recalls

Complaints317filed by owners

Crashes · fires29 · 30reported in complaints

Injuries · deaths52 · 4reported in complaints

Safety recalls

Service brakes, hydraulicMar 13, 2006

Service brakes, hydraulic

Recall 06E0220007,440 vehicles

Problem: CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Risk: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Fix: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.

Power trainApr 28, 1999

Transfer case (4-wheel drive)

Recall 99V09400010,951 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT BUSHING DISPLACEMENT CAN RESULT IN STRUCTURAL FAILURE OF THE TRANSMISSION AND/OR TRANSFER CASE. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Risk: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Fix: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

Electrical systemFeb 9, 1999

Ignition › Switch

Recall 99V029000762,201 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES WERE PRODUCED WITH A HIGHER THAN SPECIFIED ELECTRICAL LOAD THROUGH THE ACCESSORY POWER FEED CIRCUIT. THE POTENTIAL FOR CONTACT BETWEEN THE B2 (BATTERY), A2 (ACCESSORY), AND P1 (PROOF) CIRCUITS CAN OCCUR, CREATING A SHORT CIRCUIT, ALLOWING CURRENT TO FLOW THROUGH THE GROUND WIRE.
Risk: THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.
Fix: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.

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.

Power trainNov 13, 1997

Transfer case (4-wheel drive)

Recall 97V20400075,000 vehicles

Problem: VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT BUSHING DISPLACEMENT CAN RESULT IN STRUCTURAL FAILURE OF THE TRANSMISSION AND/OR TRANSFER CASE. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Risk: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Fix: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

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.

Crash test ratings

1992 Ford Aerostar

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Aerostar Van

20mpg combined

City / highway	18 / 23 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $3,350/year to fuel

Aerostar Van

18mpg combined

City / highway	16 / 22 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	15 / 22 mpg
Fuel	Regular Gasoline

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

Aerostar Wagon

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

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

Aerostar Van

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 Van AWD

16mpg combined

City / highway	14 / 18 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

15mpg combined

City / highway	14 / 18 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,450/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*
Power trainAutomatic transmission; Automatic transmission › Lever and linkage › Column shift	87	1	2	22	—
Electrical systemIgnition › Switch; Ignition	69	0	22	3	—
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Hoses, lines/piping, and fittings	63	9	3	7	—
Air bagsFrontal; Frontal › Sensor/control module	32	15	0	58	—
Engine and engine coolingEngine; Engine › Gasoline	30	1	3	22	—
Exterior lightingHeadlights; Headlights › Switch	23	0	1	0	—
EquipmentAppliance › Air conditioner; Mechanical › Carrier/rack	18	0	3	0	—
SteeringSteering wheel/handle bar; Hydraulic power assist system	17	0	4	0	—
VisibilityDefroster/defogger/hvac system › Heater core; Power window devices and controls	15	0	1	0	—
Vehicle speed controlAccelerator pedal; Cruise control	12	2	1	0	—
StructureBody › Door; Body › Door › Hinge and attachments	11	0	0	2	—
TiresTread/belt; Temporary/emergency spare tire	10	1	0	6	153,212 mi

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

Recent owner complaints

Seat belts
SEATBELT DONT WORK. *TR
Aug 15, 2008
Latches/locks/linkages
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED THE HOLES AND THE VEHICLE WAS FINE. THE MIDAS MECHANIC STATED THAT THE DEALER NEVER SEALED THE HOLES ON THE MUFFLER AND IT NEEDED TO BE REPLACED COMPLETELY. HE ALSO STATED THAT THE FUMES COULD IN FACT GET INSIDE THE PASSENGER COMPARTMENT. ALSO, THE HORN HAS NEVER WORKED ON THE VEHICLE SINCE IT WAS PURCHASED; THEREFORE, THE DEALER CONSTRUCTED…
Jun 12, 2008
Vehicle speed control › Cruise controlFire
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE CRUISE CONTROLS SHUTS ON AND OFF WITHOUT WARNING. SEVERAL YEARS AGO, HE WITNESSED BILLOWS OF SMOKE COMING FROM THE VEHICLE. THE VEHICLE HAS NOT BEEN INSPECTED OR REPAIRED. THE SPEED AND POWERTRAIN WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 145,681.
Aug 13, 2007 · 145,681 miles
Electrical system › Wiring1 injury
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE GROUND WIRES ARE SHORTING OUT THE BRAKE LIGHTS AND OTHER WIRES UNDERNEATH THE DASHBOARD. HE ALSO STATED THAT HIS WINDOWS ARE NOT WORKING. FORD STATED THAT NOTHING COULD BE DONE BECAUSE HIS VIN WAS NOT INCLUDED IN THE RECALL. THE CONTACT STATED THAT HE HAS BEEN BURNED BY THE FAILED WIRES. THE RECALL # WAS UNKNOWN. THE CURRENT MILEAGE IS 171,000 AND FAILURE MILEAGE WAS 150,000.
Jan 1, 2005 · 150,000 miles
Exterior lighting › Headlights
DT*: THE CONTACT STATED THAT THE VEHICLE'S HORIZONTAL AND VERTICAL HEADLIGHT ADJUSTERS FRACTURED ON 07/04/06. THE VEHICLE WAS TAKEN TO THE DEALER ON 07/05/06 WHO DETERMINED THAT THERE WAS NO REPLACEMENT PART AVAILABLE TO REPAIR THE PROBLEM. THE TENSION SPRING THAT ASSISTS IN THE PROPER FUNCTIONING OF THE HEADLIGHT ADJUSTERS WAS NO LONGER AVAILABLE AS WELL. THE MANUFACTURER WAS NOT ALERTED. UPDATED 8/1/2006 - *NM
Jul 4, 2006 · 171,900 miles
Power train › Manual transmission
DT*: THE CONTACT STATED WHEN THE VEHICLE WAS PLACED IN DRIVE, IT FAILED TO MOVE FORWARD. THE VEHICLE CURRENTLY ONLY OPERATES IN REVERSE. THE VEHICLE WAS SEEN BY A LOCAL MECHANIC WHO DETERMINED THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION HAD GONE OUT PREVIOUSLY AND WAS REPLACED BY A LOCAL MECHANIC.
Mar 19, 2006 · 194,000 miles
Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittingsCrash1 injury
OWNER WAS GOING AT APPROXIMATELY 45 MPH. OWNER APPLIED THE BRAKES AND THE BRAKES WENT TO THE FLOOR. OWNER SAYS THAT THE FRONT RIGHT BRAKE HOSE LINE POPPED RIGHT OFF. CAUSING THE VEHICLE TO LOSE ALL BRAKE PRESSURE PREVENTING THE VEHICLE FROM STOPPING. PROVIDE FURTHER DETAILS. *NM
Jan 20, 2005 · 68,000 miles
Tires › Tread/beltCrash
DRIVER'S SIDE REAR TIRE EXPERIENCED A TREAD SEPARATION WHILE DRIVING 60-65 MPH, WITH TWO ADULTS AND ONE CHILD IN A FORD AEROSTAR 1992 VAN. THE TIRE REMAINED INFLATED. AFTERMARKET EQUIPMENT, INSTALLED AT 136,671 MILES, TIRE SIZE P215/70R14, DOT# DBHYC2423000. *AK *NM
Sep 12, 2004 · 186,424 miles

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

LUGGAGE COMPARTMENT DOOR DROPS ABRUPTLYClosed
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.
PE02076 · opened Oct 10, 2002 · closed Mar 10, 2003
FRONT BRAKE HOSEClosed
ALLEGED THAT A FRONT BRAKE HOSE RUPTURES OR FAILS AT THE INTERFACE BETWEEN THE RUBBER HOSE AND THE BRASS FITTING
PE99035 · opened May 12, 1999 · closed Sep 23, 1999
TRANSFER CASES AND REAR DRIVE SHAFTClosedLed to recall 99V094000
There is no summary currently available
EA99002 · opened Jan 7, 1999 · closed Nov 14, 2000
TRANSFER CASES AND REAR DRIVESHAFTClosedLed to recall 97V204000
There is no summary currently available
RQ98012 · opened Jul 31, 1998 · closed Jan 7, 1999
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