Model year record

1997 Ford Aerostar recalls & problems

The 1997 Ford Aerostar has 5 safety recalls and 63 owner complaints on file with NHTSA. The most-reported problem area is electrical system (17 complaints).

Recalls5safety recalls

Complaints63filed by owners

Crashes · fires5 · 2reported in complaints

Injuries · deaths8 · 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.

Vehicle speed controlDec 26, 2000

Cables

Recall 00V42500036,500 vehicles

Problem: VEHICLE DESCRIPTION: MINIVANS EQUIPPED WITH 3.0L ENGINES. AN ACCELERATOR CABLE WAS KINKED DURING INSTALLATION, CAUSING THE CORE WIRES TO EVENTUALLY FRAY.
Risk: THIS COULD INCREASE THE FRICTION IN THE CABLE, CAUSING THE THROTTLE TO BE SLOW TO RETURN TO IDLE. THIS CONDITION COULD RESULT IN A STUCK THROTTLE.
Fix: DEALERS WILL INSTALL A NEW ACCELERATOR CABLE.

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

1997 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

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 · Automatic 4-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 5-spd · Rear-Wheel Drive · about $3,950/year to fuel

Aerostar Wagon AWD

15mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 5-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; Wiring › Interior/under dash	17	0	4	0	—
Power trainAxle assembly › Axle shaft; Automatic transmission	11	0	2	0	—
Vehicle speed controlLinkages; Cables	10	2	0	0	—
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Drum	7	1	1	0	—
WheelsRim	7	0	0	0	118,000 mi
Fuel system, gasolineDelivery › Fuel pump	4	0	1	6	—
Air bagsFrontal; On-off switch assembly	4	3	0	1	—
SuspensionFront › Wheel bearing; Front › Control arm	4	0	0	0	—
TiresTread/belt	3	0	0	0	—
Latches/locks/linkagesDoors › Latch; Hatchback/liftgate › Lock	3	0	0	1	—
SteeringHydraulic power assist › Pump; Hydraulic power assist › Hose, piping, and connections	3	0	0	0	—
Seat beltsFront › Anchorage	2	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 FOUND TWO INCOMPLETE RECALLS. I CALLED THE DEALER 9/28/2020 AT [XXX] AND SPOKE TO [XXX]. SHE PUT THE VIN IN HER SYSTEM, SAW THE TWO RECALLS AND SAID THE PARTS WOULD BE ORDERED. NO RESPONSE. I CALL [XXX] 10/5/2020 AT THE SAME NUMBER AND SHE SAID ABOUT THE SAME THING. THEN I CALLED 10/8/2020 AND ANOTHER SERVICE ADVISOR PRINTED OUT THE ISSUE WITH MY PHONE NUMBER [XXX] AND SAID [XXX] WOULD CALL ME AFTER LUNCH. NO RESPONSE. I TRIED CALLING THE FORD CUSTOMER SERVICE 800 392-3673 AND AFTER PRESSING '#' FOR TWO COMMERCIALS, THE RECORDER HUNG UP. THE VEHICLE HAS BEEN RUNNING FINE, BUT THESE ARE TWO RECALLS THAT ARE CONCERNS. (00S56 & 99S02). THANK YOU VERY MUCH. [XXX]AUGUSTA, GA INFORMATION…
Sep 28, 2020 · 160,000 miles
Engine
I WAS GIVEN THIS VAN WITH A HANDICAPPED LIFT AS A PRESENT FROM SOME PEOPLE AT OUR CHURCH. EVER SINCE I GOT IT THE ENGINE LIGHT HAS BEEN ON. I'VE HAD IT CHECKED SEVERAL TIMES BUT NO ONE SEEMS TO KNOW HOW TO FIX IT. ANOTHER PROBLEM I'VE BEEN HAVING IS THAT THE LEFT FRONT TIRE WEARS OUT MORE QUICKLY THAN THE OTHER THREE. WE'VE HAD IT BALANCED SEVERAL TIMES BUT WE STILL HAVE THAT PROBLEM EVEN WITH NEW TIRES. SINCE I AM HANDICAPPED AND USE AN ELECTRIC WHEELCHAIR IF A TIRE BLOWS OUT I MAY NOT BE ABLE TO GET OUT USING THE RAMP LIFT THAT WAS INSTALLED AND THE SAME APPLIES TO THE ENGINE. HOW DO I KNOW IF THE ENGINE HAS SOMETHING WRONG WITH IT IF THE LIGHT IS ON ALL THE TIME? *TR
Oct 8, 2005 · 100,000 miles
Vehicle speed control
NOTE: I WISH I HAD FOUND THIS SITE YEARS AGO. I COULD NOT GET PAST FORDS "BRICK WALL" TO SPEAK TO AN ENGINEER! 1. 1997 AEROSTAR - ACCELERATOR PEDAL WAS PRESSED DOWN QUICKLY TO PASS (2 LANE HIGHWAY). 2. NOW IN THE LEFT LANE, NOT FAR AHEAD OF PASSED THE CAR - I EXPERRIENCED A COMPLETE LOSS OF POWER - HARD RIGHT OVER TO SOFT SHOULDER - AVOIDED AN ONCOMING HEAD ON COLLISION - L JUST MISSED THE CAR BEING PASSED BY INCHES AND STOPPED. THE CRIMPED END OF CABLE TO THE CARBURATOR HAD RELEASED FROM THE ACCELERATOR PEDAL. 3. I CLAMPED THE CABLE BACK ONTO THE PEDAL WITH VICE GRIPS. (DROVE TO DEALER). FORD REPLACED THE CABLE. THAT PROBLEM HAS NOT HAPPENED AGAIN. (I DO NOT PRESS DOWN HARD EITHER!) *TR
Jul 15, 2002 · 48,000 miles
Wheels
OBSERVED FULL CRACK ON ALUMINUM WHEEL RIM SPOKE. THIS IS STANDARD ALUMINUM WHEEL FROM MANUFACTURER. SERIOUS SAFETY ISSUE. THIS PROBLEM SAME AS HTTP://WWW.MOTORBEAT.COM/COMPLAINT/438440/. *TR THIS IS THE SECOND RIM THAT THIS PROBLEM HAS OCCURRED. ANOTHER RIM FAILED IN THE SAME MANNER ONE YEAR AGO. REPLACED.
Jun 10, 2009 · 180,000 miles
Power train
NEED TO KNOW WERE TO START TO GET ALL THE PROBLEMS ON MY VAN TAKEN CARE OF ALL THE RECALLS, OF POWER TRAIN THE ELECTRICAL AND WHATEVER ELSE WAS REPORTED TO ME ON MY REPORT OF THE RECALLS ON THIS 1997 AREOSTAR VAN THANK YOU MARYJEAN. *TR
Mar 25, 2008
Latches/locks/linkages › Hatchback/liftgate › Lock1 injury
1997 AEROSTAR REAR HATCH: 1 OF 2 ANCHOR STUDS WHICH SUPPORT THE TAIL HATCH PNEUMATIC SPRING (VEHICLE BODY END) BROKE, ALLOWING THE HATCH TO IMMEDIATELY FALL ON TO OPERATOR. ALTHOUGH THERE ARE 2 PNEUMATIC SUPPORTS, 1 IS INSUFFCIENT TO SUPPORT THE WEIGHT OF THE HATCH. SIMILAR EXPERIENCE WITH 1994 MODEL.
Jul 20, 2005 · 99,000 miles
Electrical system › Wiring › Interior/under dashFire
MY 1997 FORD AERO STAR VAN PRODUCED A PUFF OF SMOKE FROM THE STEERING COLUMN NEAR THE IGNITION SWITCH. I TOOK IT TO MY MECHANIC WHOM CHECKED THE RECALL NOTICES AND FOUND ONE RESULTING IN AN ELECTRICAL OVERLOAD SHORT CIRCUIT AND OVERHEATING IN THE STEERING COLUMN ELECTRICAL COMPONENTS. WHEN THE KEY WAS TURNED OFF IT SUBSIDES. SINCE THIS OCCURRENCE THE INSTRUMENT PANEL HAS NOT WORKED AND BLEW ALL FUSES, THE FUEL PUMP DOES NOT TURN ON WITH THE KEY AFTER MULTIPLE ATTEMPTS IT ENGAGES SOME TIMES. THE FORD DEALER DID THE RECALL WORK BUT DID NOT FIX OR EXAMINE THE STEERING COLUMN OR THE COMPONENTS THAT BURNED OR OVER HEATED AS A RESULT OF THE OVERLOAD. [XXX] UPDATED 07/19/2012 *JS INFORMATION…
Jun 15, 2005
Wheels › Rim
CONSUMER'S HUSBAND DISCOVERED THAT ONE OF THE RIMS HAD CRACKED IN THREE PLACES. *LA ANOTHER RIM WAS FOUND WITH CRACKS IN THREE PLACES AS WELL. *SC *JB
Nov 1, 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
TRANSFER CASES AND REAR DRIVESHAFTClosedLed to recall 97V204000
There is no summary currently available
RQ98012 · opened Jul 31, 1998 · closed Jan 7, 1999