Model year record

1996 Ford Aerostar recalls & problems

The 1996 Ford Aerostar has 6 safety recalls and 104 owner complaints on file with NHTSA. The most-reported problem area is wheels (23 complaints).

Recalls6safety recalls

Complaints104filed by owners

Crashes · fires9 · 4reported in complaints

Injuries · deaths7 · 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.

EquipmentAug 29, 1996

Other › Labels

Recall 96V161000134,770 vehicles

Problem: THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Risk: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .
Fix: OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.

Latches/locks/linkagesApr 22, 1996

Doors › Latch

Recall 96V07000073,500 vehicles

Problem: WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."
Risk: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.
Fix: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.

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

1996 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

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 / 21 mpg
Fuel	Regular Gasoline

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

Aerostar Wagon AWD

15mpg combined

City / highway	13 / 19 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*
WheelsRim	23	0	0	0	124,000 mi
Service brakes, hydraulicFoundation components › Disc › Rotor; Antilock/traction control/electronic limited slip	21	4	0	1	—
Power trainAutomatic transmission; Driveline › Driveshaft	14	0	0	0	187,000 mi
Electrical systemIgnition › Switch; Ignition	13	0	3	0	107,000 mi
SteeringHydraulic power assist system; Linkages › Knuckle › Spindle › Arm	9	0	0	0	—
Air bagsFrontal; Side/window	7	7	0	6	—
Latches/locks/linkagesDoors › Latch	6	0	0	0	—
TiresTread/belt	5	0	0	0	99,500 mi
StructureBody › Door; Body	4	1	0	0	—
Vehicle speed controlCruise control; Linkages	4	1	0	0	—
EquipmentAppliance › Air conditioner; Electrical › Radio/tape deck/cd etc.	3	0	0	0	—
SeatsFront assembly › Recliner	3	0	0	0	—

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

Recent owner complaints

Structure › Body
CONDENSED VERSION: @ 70MPH POSTED SPEED LIMIT GOODYEAR ALLEGRA TOURING TIRE EXPLODED LIKE A 1/4 STICK OF DYNAMITE AND ALMOST COST ME MY LIFE IF MY REACTIONARY TIME HAD BEEN ANY SLOWER. 3 OTHER TIRES SAME LEAKING THROUGH SIDEWALL GOODYEAR DECORATIVE GILLS ON SAME THIS HAS NOT RESOLVED. SELLER HAS NOT RESOLVED AND REFUSES THOUGH GOODYEAR SAID TO REPLACE BEFORE THE MAIN ISSUE OF THE LEFT FRONT DRIVER TIRE EXPLODING AT 70 MPH, . LITIGATION IS NEXT STEP IF AMICABLE RESOLUTION CAN NOT BE HAD. CONTACT HAS BEEN EXTENSIVE WITH GOODYEAR TO NO RESULTS.
Jul 2, 2019
Electrical systemFire
I HAD SMOKE AND ACRID SMELL COMING FROM UNDER MY DASH (WHILE DRIVING), WHERE THE STEERING COLUMN FITS TO IT. I HAVE CONTACTED A MAJOR FORD DEALER (BRANDON FORD), AND THEY ARE REFUSING TO HELP ME. I CALLED FORD CUSTOMER SERVICE AND HE SAID MY VIN IS NOT LISTED FOR A RECALL, BUT YET HAD NO ANSWER FOR ME WHEN I ASKED WHY IS MY VEHICLE NOT ON THE RECALL LIST, WHEN IT IS IN THE GROUP OF VEHICLES THAT WERE RECALLED AND THAT ARE CATCHING ON FIRE WHILE DRIVING DOWN THE ROAD. OVER 887,000 WERE RECALLED FOR FIRE RELATED PROBLEMS, BUT THEY REFUSE TO EVEN LOOK AT MINE. SO, CAN I KEEP DRIVING IT? I DON'T KNOW IF IT WAS A ONE TIME THING, OR WHAT.....
Aug 23, 2017 · 107,000 miles
Seat belts
12/6/2014 @ 18:20 C.S.T. TO WHOM IT MAY CONCERN, (HOPEFULLY A SUPERVISOR OR DIRECTOR) THE DRIVERS SIDE SEAT BELT FLOOR CLASP FAILS. I RELEASES THE SEAT BELT WHILE DRIVING. AFTER TWO OR THREE TIMES OF RE-HOOKING THE SEAT-BELT TO THE HOLD DOWN CLASP BOLTED THROUGH FLOOR BOARD OF THE VEHICLE, IT WILL NO LONGER ACCEPT AND HOLD THE SEAT BELT IN PLACE. THIS HAS HAPPENED TO BOTH OF MY VEHICLES, THE 1993 OCCURRED AT APPX. 190,000 MILES AND WHEN I CONTACTED FORD ABOUT THIS SAFETY ISSUE AND FAILURE OF THE SEAT BELT TO REMAIN CLASPED, THEY SIMPLY SAID, IT IS AN OLDER VEHICLE AND YOU HAVE TO PURCHASE THE ENTIRE SEAT BELT ASSEMBLY FOR OVER $500.00...[XXX]. THIS IS A SAFETY ISSUE...AND FORD NEEDS TO…
Nov 19, 2014 · 158,000 miles
Power train
TL* THE CONTACT OWNS A 1996 FORD AEROSTAR. WHILE DRIVING APPROXIMATELY 50 MPH THE FRONT DRIVERS SIDE TIRE BEGAN TO VIBRATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN STATED THE TRANSFER CASE WOULD HAVE TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. NHTSA RECALL CAMPAIGN ID NUMBER: 97V204000 (POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)) MAY BE RELATED TO THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THE VIN WAS NOT INCLUDED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.
May 1, 2011 · 160,000 miles
Wheels
TL*THE CONTACT OWNS A 1996 FORD AEROSTAR. WHILE DRIVING 50 MPH, THE CONTACT HEARD A LOUD ROARING SOUND. SHE STOPPED THE VEHICLE AND NOTICED THAT THE REAR PASSENGER WHEEL SPOKES FAILED. THE WHEEL WAS REPLACED WITH A SPARE TIRE. THERE WAS NO DAMAGE TO THE TIRE OR VEHICLE. THE WHEEL WAS INSPECTED BY THE REPAIR SHOP AND THEY STATED THAT THE WHEEL WAS DEFECTIVE. THE WHEELS WERE THE ORIGINAL WHEELS FOR THE VEHICLE. THE POWERTRAIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 58,000.
Oct 28, 2007 · 58,000 miles
Electrical system › Ignition › Switch
DT*: THE CONTACT STATED WHILE THE VEHICLE WAS BEING DRIVEN 30 MPH, ALL POWER FAILED AND THE ENGINE STALLED. THE STALLING HAS ALSO OCCURRED AT HIGHER SPEEDS AND WHILE THE VEHICLE WAS IMMOBILE. A FUSE CONNECTED TO THE BATTERY CABLES BLEW. WHEN THE FUSE WAS REPLACED, THE ENGINE WOULD RESTART. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER. THE CONTACT WAS INFORMED THE VEHICLE WAS NOT INCLUDED IN RECALL # 99V029000, FOR THE ELECTRICAL IGNITION SWITCH DUE THE VIN EVEN THOUGHT VEHICLE HAD THE SAME PROBLEMS. THE MANUFACTURER WAS NOT NOTIFIED.*AK
Dec 11, 2006 · 115,000 miles
Power train › Driveline › Driveshaft
DT*: THE CONTACT STATED THE VEHICLE WAS TAKEN TO A TIRE DEALER FOR REPLACEMENT OF THE TIRES. AFTER THE TIRES WERE REPLACED AND VEHICLE WAS BEING DRIVEN HOME AT 45MPH, THE VEHICLE HESITATED AS IF THE GEARS WERE NOT CHANGING PROPERLY. THE VEHICLE WAS RETURNED TO THE TIRE DEALER WHO DETERMINED THE DRIVE SHAFT WAS LOOSE. THE DEALER RECOMMENDED THE VEHICLE NOT BE USED UNTIL THE DRIVE SHAFT WAS WELDED AND THE UNIVERSAL JOINT WAS REPLACED.
May 4, 2006 · 214,000 miles
Wheels
DT*: THE CONTACT STATED THE FRONT WHEELS ON THE VEHICLE CRACKED. THIS WAS NOTICED FROM A VISUAL INSPECTION BY THE CONTACT. THE MANUFACTURER WAS ALERTED AND STATED THE WHEELS CRACKED UNDER STRESS FROM THE VEHICLE.
Mar 20, 2006 · 124,000 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

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