Model year record

1994 Ford Aerostar recalls & problems

The 1994 Ford Aerostar has 5 safety recalls and 257 owner complaints on file with NHTSA. The most-reported problem area is electrical system (79 complaints).

Recalls5safety recalls

Complaints257filed by owners

Crashes · fires22 · 28reported in complaints

Injuries · deaths33 · 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.

Electrical systemFeb 9, 1999

Wiring › Front underhood

Recall 99V02800023,097 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.
Risk: HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.
Fix: DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.

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

1994 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 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 Van

16mpg combined

City / highway	14 / 19 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	14 / 19 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*
Electrical systemIgnition › Switch; Horn	79	0	20	3	120,000 mi
Power trainAutomatic transmission; Automatic transmission › Lever and linkage › Column shift	48	0	3	6	—
Air bagsFrontal; Frontal › Sensor/control module	45	17	0	10	120,000 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components	28	2	0	0	—
Engine and engine coolingEngine; Engine › Gasoline	25	0	3	3	—
SteeringSteering wheel/handle bar; Rack and pinion	22	2	0	2	120,000 mi
Fuel system, gasolineDelivery › Fuel pump; Storage › Tank assembly	19	1	5	8	—
StructureBody › Door; Body › Hatchback/liftgate › Support device/strut	16	1	1	2	—
SuspensionFront › Shock absorber; Rear	13	0	0	0	120,000 mi
Seat beltsFront › Buckle assembly; Front › Anchorage	12	2	0	0	—
Vehicle speed controlAccelerator pedal; Cruise control	12	1	0	0	—
Exterior lightingHeadlights; Headlights › High/low beam dimmer switch	12	0	1	0	120,000 mi

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

Recent owner complaints

Air bags
AIRBAG (CODE 13 AND 51) LIGHTS FLASHING
Sep 10, 2017
Electrical systemFire
VAN HAD BEEN DRIVEN FOR APPROXIMATELY TWO HOURS OR SO, AROUND THE LOCAL CITY COMMUNITIES. VAN HAD BEEN PARKED FOR APPROXIMATELY FIVE MINUTES, WHEN NEIGHBORS NOTIFIED ME OF FIRE. INTENSE FIRE WAS COMING FROM DRIVER'S SIDE/WINDSHIELD/IGNITION/FRONT SEAT AREA, EVENTUALLY CONSUMING ENTIRE INTERIOR OF VAN. NORFOLK FIRE DEPARTMENT RESPONDED WITHIN FIVE MINUTES, OR SO, STATION ONLY ABOUT 150 YARDS FROM MY RESIDENCE. FIRE WAS EXTINGUISHED WITHIN FIVE MINUTES OR SO, BUT THE VAN WAS COMPLETELY CONSUMED BY FIRE AND TOTALLY DESTROYED BY THEN. VAN WAS JUNKED/SALVAGED. PAID ONLY $100.00 FOR SALVAGE/JUNK/TOWING, ETC. PRIOR TO THIS INCIDENT, I HAD NO PROBLEMS WITH MY VAN. VAN ONLY HAD 93000 MILES. HAD…
Jul 20, 2013 · 93,000 miles
Electrical system
HAD THE CLOCK RING REPAIRED (YEAR 2000)DUE TO THE AIRBAG LIGHT STAYED ON. NOW THE AIRBAG LIGHT STAYS ON ,THERE IS NO HORN AND THE CRUISE CONTROL DOESNT WORK. THERE HAS TO BE A RECALL FOR THIS SAFETY PROBLEM. *TR
May 9, 2001
Fuel system, gasoline
WE WERE BEGINNING TO EXPERIENCE LOSS OF POWER. THE FUEL PUMP AND FILTER WAS CHANGED. WE ARE STILL GETTING INTERMITTENT LOSS OF POWER, BUT WHAT MY CONCERN IS THAT I SAW A RECALL ON NHTSA: 99V028000. I WAS MADE AWARE OF THIS RECALL WHEN I VIEWED AN EPISODE OF COPS WHERE AN AEROSTAR'S ELECTRICAL SYSTEM CAUSED A FIRE IN THE ENGINE COMPARTMENT. I CALLED FORD IN TEMECULA CALIF AND NOW THEY HAVE NO RECORD OF ANY RECALLS FOR THIS YEAR OF AEROSTAR 1994 I DO HAVE KIDS AND I WOULD LIKE TO KNOW WHAT SAFETY MATTERS REMAIN ON THIS VAN. *TR
Jun 1, 2008
Air bags
ALL ELECTRONICS ON STEERING COLUMN DON'T WORK. AIR BAG SYSTEM FLASHES 3-2. NO AIRBAG (PRESUMABLY), CRUISE CONTROL OR HORN FUNCTION. *TR
Oct 18, 2007 · 120,000 miles
Suspension › Rear › Springs › Coil springs
FRONT COIL SPRINGS SNAPPED, HAD TO REPLACED WITH READING SPRING WORKS, THEY HAD TO SEND THE SPECKS TO CHICAGO. MY FORD AERO STAR 4 WHEEL DRIVE & 4.0 V6 IS NOT AVAILABLE FROM AFTER MARKET. THE ONLY OPTION IS TO BUY NEW OR USED FORD SPRINGS WHICH ARE MADE IN CHINA. THE LOCAL FORD DEALER ADMITS REPLACING COIL & LEAF SPRINGS ON SEVERAL MODELS. MIDAS WAS SO BUSY REPLACING FORD SPRINGS, THEY COULD NOT SET UP AN APPOINTMENT TO INSTALL SPRINGS EVEN IF I HAD THE SPRINGS. *TR
Jun 20, 2006 · 120,000 miles
Electrical system › IgnitionFire
CAR WAS PARKED IN DRIVEWAY, UNTOUCHED, FOR AT LEAST 24 HOURS. FIRE ERUPTED ABOUT 7:00 AM. FLAMES WERE COMING THROUGH THE DRIVERS SIDE WINDSHIELD. SEEMED TO BE ELECTRICAL IN NATURE. CAR IS A TOTAL LOSS. CAR IS COMPLETELY ORIGINAL (NO ELECTRIC ALTERATIONS). CAR HAD BEEN TO THE DEALER WITHIN THE LAST 2 YEARS SO ANY RECALL WORK SHOULD HAVE BEEN DONE. *TR
Jan 26, 2008 · 110,000 miles
Steering › Steering wheel/handle bar
THE SEAMS IN THE STEERING WHEEL OOZE BLACK GOO AND FORM DIME SIZED POOLS AROUND THE INSIDE CENTER WHERE THE AIRBAG IS PACKED ...THE DEALER SAID JUST BUY A COVER BUT IT CONTINUES TO LEAK AS A NEW STEERING WHEEL WOULD BE VERY COSTLY DUE TO AIRBAG, I WORRY IF AIRBAG WILL DEPLOY CORRECTLY IN A CRASH. *JB
Mar 1, 2004 · 200,000 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