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1991 Ford Aerostar

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 1991 Ford Aerostar do not stand out strongly from the model-year median of 135.5.

About this comparison →

How this year compares

Owner complaints by model year

Compare all Aerostar years →

Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

Limited mileage data: 2 of 223 reports include usable mileage. There isn’t enough coverage to show a useful chart.

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 67 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 31 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

23 crash reports68 fire reports14 injury reports

Equipment complaints

14 reports
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Mileage unknown · Jun 27, 2002
Equipment

I WENT TO FIRESTONE IN ST. JOE, MO AND HAD MY AIR CONDITIONING RECHARGED AFTER 9 YEARS OF DRIVING MY VAN. THEY TOLD ME THAT I NEEDED TO REPLACE A HOSE ON THE FRONT OF THE VECHICAL AND THAT THEY NEEDED TO THEN ADD FREON TO THE SYSTEM. THAT WAS IN JULY 19, 2001. IT DIDN'T SEEM AS COLD AS IT HAD BEFORE BUT IT WAS OK. THEN WHEN I …

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I WENT TO FIRESTONE IN ST. JOE, MO AND HAD MY AIR CONDITIONING RECHARGED AFTER 9 YEARS OF DRIVING MY VAN. THEY TOLD ME THAT I NEEDED TO REPLACE A HOSE ON THE FRONT OF THE VECHICAL AND THAT THEY NEEDED TO THEN ADD FREON TO THE SYSTEM. THAT WAS IN JULY 19, 2001. IT DIDN'T SEEM AS COLD AS IT HAD BEFORE BUT IT WAS OK. THEN WHEN I NEEDED THE AIR THIS SUMMER I HAD NONE. THEY SAID THAT THE HOSE THAT THEY INSTALLED THEY LATTER WERE TOLD WOULDN'T HOLD THE PRESSURE (I THINK) BUT THAT NOW SENCE IT WAS OVER 6 MONTHS THEY WOULDN'T OR COULDN'T DO ANYTHING. IT COST ME $304.07. THEY SAY THAT YOU PEOPLE KNEW ABOUT THIS PROBLEM. WHAT THE HELL IS GOING ON?*AK

NHTSA ODI #763566

Mileage unknown · Aug 29, 2000
EquipmentPower TrainVisibility

A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP REPLACING WHOLE REAR AXLE ASSEMB…

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A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP REPLACING WHOLE REAR AXLE ASSEMBLY AND DIFFERENTIAL FROM SALVAGE YARD MYSELF BECAUSE IT WAS MUCH LESS EXPENSIVE THAN WHAT THE REPAIR PLACE WANTED. TRANSMISSION BEGAN SLIPPING DURING ACCELERATION. AFTER A COUPLE DAYS IT QUIT MOVING THE VEHICLE COMPLETELY, AS IF IT WERE IN NEUTRAL. I REPLACED THE TRANSMISSION WITH ONE FROM A SALVAGE YARD SINCE, ONCE AGAIN, IT WAS THE LEAST EXPENSIVE WAY TO GO. THE HEATER CORE RECENTLY BEGAN TO LEAK INSIDE THE VEHICLE AND STEAM UP THE WINDOWS. THE HEATER CORE HAS BEEN CAPPED OFF AND NOT YET REPLACED. FINALLY, JUST TWO DAYS AGO THE ENGINE BEGAN RUNNING VERY ROUGH AND INTERMITTENTLY STALLED. LOOKING UNDER THE HOOD REVEALED THERE WAS NO WATER IN THE RADIATOR. UPON RESERVICING THE RADIATOR AND STARTING THE ENGINE WATER WAS NOTICED POURING OUT OF THE EXHAUST PIPE. I CAN ONLY PRESUME EITHER THE HEAD GASKET HAS FAILED OR THE CYLINDER WALL IS CRACKED PERMITTING THE COOLANT WATER TO ENTER THE COMBUSTION CHAMBER. THE VEHICLE IS CURRENTLY UNDRIVEABLE AND PARKED WHILE MY WIFE AND I TRY TO FIGURE OUT HOW TO AFFORD TO FIX YET ANOTHER PROBLEM WITH THIS PIECE OF TRASH FORD AEROSTAR.

NHTSA ODI #729454

Mileage unknown · Jul 11, 2000
EquipmentFire

VEHICLE CAUGHT ON FIRE. FIRE MARSHALL & INSURANCE COMPANY SAID THE CAUSE SEEM TO BE THE A/C BLOWER MOTOR FAN. DEALER IS LOOKING INTO THE PROBABLE REASON.*AK

NHTSA ODI #865215

Mileage unknown · Feb 23, 1999
Equipment

SPARE TIRE LOCATED UNDER REAR OF VEHICLE IS HELD UP BY A CABLE. THE CABLE BROKE WHILE SITTING IN THE DRIVEWAY. THE SPARE TIRE FELL TO THE GROUND. I HATE TO THINK WHAT WOULD HAVE HAPPENED IF I WAS DRIVING 65MPH WHEN IT FELL. DEALER DID NOT SEEM INTERESTED.

NHTSA ODI #703673

Mileage unknown · Jun 24, 1998
Equipment

SPARE TIRE RACK CABLE RUSTED CAUSING TIRE TO FALL OFF.

NHTSA ODI #604703

Mileage unknown · Jul 16, 1997
EquipmentPower TrainService Brakes, Hydraulic

BRAKES FAILED.

NHTSA ODI #519494

Mileage unknown · Feb 11, 1997
EquipmentService Brakes, Hydraulic

REAR ANTI-LOCK SIGNAL LIGHT COMPUTER SHOWS UP CONTINUOSLY WHEN IGNITION IS ON AND STAYS ON UNTIL IGNITION IS DISENGAGED.

NHTSA ODI #514728

Mileage unknown · Jan 17, 1996
EquipmentService Brakes, HydraulicSteering

WINDSHIELD WIPER MECHANISM FELL OFF, CAUSING POOR VISIBILITY. *SD

NHTSA ODI #500755

Mileage unknown · Jan 10, 1996
EquipmentPower TrainService Brakes, Hydraulic

MASTER CYLINDER REPLACED. *SD

NHTSA ODI #500822

Mileage unknown · Sep 8, 1995
Equipment

FACTORY ROOF RACK BROKE WHEN IN USE SENDING DEBRIS ONTO HIGHWAY; SCREW THAT HOLDS ROOF RACK DOWN IS LESS THAN AN INCH, VERY SMALL; ROOF RACK BAR CAME LOOSE. TT

NHTSA ODI #971812

Official recalls

3

96V071000 · Electrical System:ignition

Apr 25, 1996

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence & remedy

Consequence: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

91V189000 · Power Train:automatic Transmission

Nov 4, 1991

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Consequence & remedy

Consequence: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VEHICLE ACCIDENT.

Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

91V164000 · Seat Belts:front:anchorage

Sep 20, 1991

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.

Consequence & remedy

Consequence: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.

Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA99002 · Transfer Cases And Rear Drive Shaft

Opened Jan 7, 1999 · Closed Nov 14, 2000

Status: closed (inferred from source dates) · Power Train

There is no summary currently available

RQ97015 · Parking Pawl

Opened Oct 29, 1997 · Closed Apr 1, 1999

Status: closed (inferred from source dates) · Power Train:automatic Transmission

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