IllustrationTHE FLYWHEEL HAS BEEN REPLACED 5 TIMES. IT CONTINUES TO TEAR APART NEAR WHERE IT IS BOLTED ON. THIS IS AN ONGOING PROBLEM THAT WE CANNOT SOLVE. MY MECHANIC CANNOT DETERMINE WHY THIS CONTINUES TO HAPPEN. *AK
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
What owners actually said
223 reportsONGOING PROBLEM WITH SEVERE VIBRATION WHILE TRAVELING AT 50 MPH. VEHICLE BEEN IN DEALER SHOP ON SEVERAL OCCASIONS, BUT PROBLEM STILL OCCURS. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK
NO SUMMARY( DOT NUMBER: )
NO SUMMARY( DOT NUMBER: )
VEHICLE CAUGHT ON FIRE IN UNDER DASH. VEHICLE WAS TOTALED. DEALER COULD NOT DETERMINE THE CAUSE OF THE FIRE. *AK THE 1991 FORD AEROSTAR HAD A RECALL FOR THE IGNITION COLUMN (96V-071). THE DEALER CLAIMS TO HAVE FIXED IT BUT IT CAUGHT FIRE. *YH
BRIDGESTONE TURANZA TIRES P215 70 R14 EXPERIENCED TREAD SEPARATION, CAUSING DAMAGE TO VEHICLE. *SLC
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.
CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD HIM THAT HIS VEHICLE WASN'T ON…
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CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD HIM THAT HIS VEHICLE WASN'T ON RECALL.*AK
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
VEHICLE SUDDENLY ACCELERATED WHILE BEING PLACED INTO REVERSE AT A HIGH SPEED. VEHICLE HAD TO BE STOPPED BY TURNNING OFF THE KEY. DEALER HAS BEEN CONTACTED. *AK *ML
Official recalls
396V071000 · 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
2EA99002 · 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