Model year record

1993 Ford Aerostar recalls & problems

The 1993 Ford Aerostar has 4 safety recalls and 374 owner complaints on file with NHTSA. The most-reported problem area is electrical system (110 complaints).

Recalls4safety recalls

Complaints374filed by owners

Crashes · fires37 · 38reported in complaints

Injuries · deaths35 · 0reported 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.

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

1993 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

19mpg combined

City / highway	17 / 23 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 / 22 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Automatic 4-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 Van AWD

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-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 Wagon

17mpg combined

City / highway	15 / 22 mpg
Fuel	Regular Gasoline

3 L · 6 cyl · Manual 5-spd · Rear-Wheel Drive · about $3,950/year to fuel

Aerostar Wagon

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 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

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; Ignition	110	0	36	0	150,000 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components	77	6	0	1	—
Power trainAutomatic transmission › Lever and linkage › Column shift; Automatic transmission	75	5	3	6	—
Air bagsFrontal; Frontal › Sensor/control module	38	23	0	23	—
Engine and engine coolingEngine › Gasoline; Engine	34	0	4	0	—
EquipmentAppliance › Air conditioner; Mechanical › Accessory scissor/screw/bottle jack/lift	28	0	0	0	—
StructureBody › Door; Body	25	1	1	2	—
SuspensionRear; Front	25	0	0	0	—
Vehicle speed controlCruise control; Springs	24	5	0	0	—
SteeringHydraulic power assist system; Steering wheel/handle bar	20	1	0	0	—
VisibilityPower window devices and controls; Defroster/defogger/hvac system › Heater core	13	0	1	0	—
Fuel system, gasolineDelivery › Fuel pump; Storage › Tank assembly	13	0	2	0	—

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

Recent owner complaints

Power train
TL* THE CONTACT OWNS A 1993 FORD AEROSTAR. WHILE DRIVING AT APPROXIMATELY 80 MPH, THERE WAS A VIBRATION COMING FROM THE DRIVER SIDE AND THERE WAS FLUID LEAKING FROM THE VEHICLE. THE CONTACT NOTICED THAT THE TRANSMISSION TRANSFER CASE WAS FRACTURED AND FLUID WAS LEAKING. THE VEHICLE WAS TOWED TO THE CONTACTS RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.
Oct 26, 2015
Electrical system
TL* THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT THE KEY BECAME LODGED IN THE IGNITION. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR A DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 169,000.
Jul 4, 2011 · 169,000 miles
Structure › Body › BumpersCrash
BACKED INTO PINE TREE IN DRIVEWAY. SHATTERED PLASTIC BUMPER COVER. CAN NOT REPLACE BUMPER COVER BECAUSE FORD SAYS OBSOLETE. ALSO NO AFTER MARKET BUMPER CAN BE FOUND FOR THIS MODEL. THIS BUMPER PROTECTS NO ONE. *JS FORD WON'T EVEN GIVE ME THE FORD PART NUMBER. ITS A CARGO VAN. OTHER MODEL COVERS CAN BE BOUGHT FROM AFTER MARKET SELLERS BUT NOT THE CARGO VAN. ONLY PLACE TO GET ONE IS JUNK YARDS IF YOU ARE GET LUCKY. MOST OF THEIR COVERS ARE BUSTED ALSO. A CAR IS A HAZARD WITHOUT A BUMPER. *JS
May 1, 2014 · 100,000 miles
Electrical system › Ignition › Switch
TL*THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT HE NOTICED ELECTRICAL PROBLEMS. THERE WAS A CLICKING SOUND AND HE COULD FEEL A PULSATION IN THE DASHBOARD; THERE WERE ALSO ELECTRICAL SHORTAGES. HE CALLED THE DEALERSHIP ABOUT RECALL 99V029000 AND WAS TOLD THAT HIS VEHICLE WAS NOT INCLUDED IN THE RECALL. HE ALSO CONSULTED THE MANUFACTURER AND IT WAS CONFIRMED THAT THE VEHICLE WAS NOT INCLUDED. THE VEHICLE HAD NOT BEEN REPAIRED TO-DATE. THE CURRENT MILEAGE WAS 144,705. THE FAILURE MILEAGE WAS APPROXIMATELY 144,670. UPDATED 02/22/11
Nov 5, 2009 · 144,670 miles
Electrical systemFire
TL*THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT HIS VEHICLE WAS 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; THEREFORE, CREATING A SHORT CIRCUIT AND ALLOWING CURRENT TO FLOW THROUGH THE GROUND WIRE. ON NUMEROUS OCCASIONS, HE NOTICED THAT THE SWITCH MODULE MELTED AND THE INSTRUMENT CONTROL PANEL LIGHTING WAS INOPERATIVE. AS A RESULT, THE RISK OF A SEVERE FIRE INCREASED. THE MANUFACTURER STATED THAT THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 99V029000 (ELECTRICAL SYSTEM:IGNITION:SWITCH); THEREFORE, THEY WOULD NOT…
Jul 16, 2006 · 168,000 miles
Tires
BOUGHT FOUR TIRES: SIGMA SHADOW. 55,000 MILES WARRANTY. 215/75R14, 6K60, AT TIRE KINGDOM LOCATED AT: 8790 SW 24TH ST. MIAMI, FL. 33165. TELEPHONE 305 227 4110. *TR ON OCT. 22, 2007 THE REAR RIGHT TIRE BLEWOUT. THE TIRE HAD 7,194 MILES. TIRE KINGDOM GAVE ME TWO TIRES WHICH THEY INSTALLED IN THE FRONT. ON NOV. 19, 2007 ANOTHER TIRE BLEWOUT. THIS TIRE HAD 10,550 MILES. THIS LAST INCIDENT HAPPENED IN HOUSTON. I WENT TO NTB (PART OF THE SAME COMPANY) LOCATED AT: 7115 FM 1960 ROAD WEST. TELEPHONE 281- 580-1689. I TALKED TO THE MGR. MR. FRED JOHNSON. I SHOWED HIM THE BLOWNOUT TIRE, ALL THE PAPERS ETC..AND ASKED HIM TO REPLACE THE BLOWNOUT TIRE PLUS THE OTHER ORIGINAL TIRE. HE SAID THAT HE WOULD…
Oct 22, 2007 · 7,194 miles
Electrical systemFire
JUST GOT HOME AND WAS PARKED IN FRONT OF THE HOUSE. ABOUT 30 MIN LATER SOMEONE WAS KNOCKING ON ARE DOOR TELLING US THE VAN WAS ON FIRE. THERE WAS NO KEYS LEFT IN THE VAN. THE FIRE BURN THE DASH AND THE RIGHT SIDE OF THE INSIDE OF THE ENGINE AND THE HOOD. THE VAN IS NOW TOTAL. *NM
Nov 10, 2006
Engine and engine cooling
DT*: THE CONTACT STATED UPON CHANGING BOTH THE FUEL FILTER AND THE OIL FILTER, THE VEHICLE MADE A KNOCKING NOISE WHILE DRIVING 20 MPH. THE VEHICLE WAS TAKEN TO A PRIVATE REPAIR SHOP WHO WAS UNABLE TO DETERMINE THE CAUSE OF THE PROBLEM.
Nov 3, 2006 · 146,000 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
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
FUEL SENDER ASSEMBLY FIRESClosedLed to recall 99V028000
There is no summary currently available
EA98016 · opened Jul 14, 1998 · closed Feb 12, 1999
FUEL SENDER ASSEMBLY FIRESClosed
OWNERS ALLEGE THAT FAILURE OF THE FUEL PUMP/SENDER CONNECTOR RESULTS IN SHORT CIRCUIT THAT HAS RESULTED IN VEHICLE FIRES.SYMPTOMS INCLUDE ERRATIC FUEL GAUGE OPERATION, , SMOKE FROM THE DASH ON THE DRIVER'S SIDE NEAR THE STEERING COLUMN (FUEL PUMP FUSIBLE LINK) AND PASSENGER SIDE (FUEL PUMP INERTIA CUTOFF SWITCH), INTERMITTENT STALL AND NO START CONCERNS, AND A BURNING ODOR. SEVERAL INCIDENTS HAVE RESULTED IN DAMAGE TO PLASTIC FUEL TUBES AND/OR FUEL SUPPLY/RETURN TUBES.
PE98010 · opened Feb 13, 1998 · closed Jul 14, 1998