BRAKE LIGHTS CONSTANTLY SHORTING OUT. I HAVE TO REPLACE THEM 2 OR MORE TIMES PER YEAR. I USE LONG-LIFE BULBS, BUT THEY CONTINUALLY GO OUT. I SEE MANY OTHER AEROSTAR VEHICLES WITH SIMILAR SITUATION. WHILE THIS HAS NOT CAUSED AN ACCIDENT YET, UNLESS I CONSTANTLY CHECK THE LIGHTS, I MAY BE INVOLVED IN AN ACCIDENT AND/OR TICKET …
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BRAKE LIGHTS CONSTANTLY SHORTING OUT. I HAVE TO REPLACE THEM 2 OR MORE TIMES PER YEAR. I USE LONG-LIFE BULBS, BUT THEY CONTINUALLY GO OUT. I SEE MANY OTHER AEROSTAR VEHICLES WITH SIMILAR SITUATION. WHILE THIS HAS NOT CAUSED AN ACCIDENT YET, UNLESS I CONSTANTLY CHECK THE LIGHTS, I MAY BE INVOLVED IN AN ACCIDENT AND/OR TICKET DUE TO THIS DEFECT. *NM
NHTSA ODI #10112157
149,000 miles · Dec 16, 2004
Exterior Lighting
HEADLIGHTS SWITCH BURNED OUT TWICE. THE CONNECTOR TO THE SWITCH KEPT BURNING. THE MANUFACTURER OFFERED NO HELP.*AK
NHTSA ODI #10104971
Mileage unknown · Sep 20, 2000
Exterior Lighting
HEADLIGHTS BEGAN ERRATIC OFF & ON CYCLE --- HAD TO DRIVE THAT WAY FOR ABOUT 10 MINUTES TO REACH HOME --- CALLED FORD SERVICE DEPT TODAY --- THEY STATED THE HEADLIGHT SWITCH HAS A BUILTIN BREAKER --- SWITCH WOULD HAVE TO BE REPLACED, THAT THEY HAD PART IN STOCK, HAD SEEN OTHER FAILURES OF THIS SWITCH ASM --- THIS IS POTENTIALLY …
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HEADLIGHTS BEGAN ERRATIC OFF & ON CYCLE --- HAD TO DRIVE THAT WAY FOR ABOUT 10 MINUTES TO REACH HOME --- CALLED FORD SERVICE DEPT TODAY --- THEY STATED THE HEADLIGHT SWITCH HAS A BUILTIN BREAKER --- SWITCH WOULD HAVE TO BE REPLACED, THAT THEY HAD PART IN STOCK, HAD SEEN OTHER FAILURES OF THIS SWITCH ASM --- THIS IS POTENTIALLY A LIFE THREATENING FAILURE --- PERSONAL SAFETY IS DEFINITELY COMPRISED BY THE SWITCH FAILURE. *AK
NHTSA ODI #732061
Mileage unknown · Aug 4, 2000
Exterior Lighting
UNABLE TO READ LED INSTRUMENTS QUANTITIES, WARNINGS OR SPEEDOMETER WITH HEADLIGHTS ON DURING DAYLIGHT HOURS WITH SUNLIGHT OR BRIGHT CLOUDS. THE GREEN LED LUMINOUS DIMMER IS ON MINIMUM. THIS DEFECT COULD LEAD TO ENGINE DAMAGE AND/OR EXCESSIVE SPEED. THE LED LUMINOUS IS BRIGHTER WITH LIGHTS OFF DURING THE DAY, BUT COMPANY TRAIN…
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UNABLE TO READ LED INSTRUMENTS QUANTITIES, WARNINGS OR SPEEDOMETER WITH HEADLIGHTS ON DURING DAYLIGHT HOURS WITH SUNLIGHT OR BRIGHT CLOUDS. THE GREEN LED LUMINOUS DIMMER IS ON MINIMUM. THIS DEFECT COULD LEAD TO ENGINE DAMAGE AND/OR EXCESSIVE SPEED. THE LED LUMINOUS IS BRIGHTER WITH LIGHTS OFF DURING THE DAY, BUT COMPANY TRAINING AND NATIONAL SAFETY INDICATES THAT IT IS SAFER TO DRIVE WITH LIGHTS ON AT ALL TIMES. THE DEALER HAS CONTENDED THAT THE LIGHTS SHOULD NOT BE ON DURING THE DAY.
NHTSA ODI #726598
Mileage unknown · Apr 6, 2000
Exterior Lighting
THE BRAKES LIGHTS STARTED W/ FLICKERING ON/OFF WHEN BRAKING. AFTER MONTHS OF THIS, BRAKES LIGHT DOES NOT WORK AT ALL. WE HAVE REPLACED FUSES AND BULBS AND THEY CONTINUE TO BURN OUT WITHIN DAYS.
NHTSA ODI #721107
Mileage unknown · Aug 9, 1999
Exterior LightingFire
THE HEADLIGHT SWITCH MELTED AND BURNED WHICH RESULTED IN A FIRE. PLEASE PROVIDE FURTHER INFORMATION. *AK
NHTSA ODI #844634
Mileage unknown · Sep 6, 1998
Electrical SystemExterior LightingPower Train
HIGH BEAM SWITCH/HORN BUTTON, AND TRANSFER CASE FAILED.
NHTSA ODI #540625
Mileage unknown · May 20, 1996
Exterior Lighting
UPON BRAKING, REAR BRAKE LIGHTS ILLUMINATE BUT FLICK INTERMITTENTLY SOMETIMES NOT AT ALL. OWNER HAD OTHERS DATING BACK TO 1986 W/SAME PROBLEM. DESCRIBE. *AK
NHTSA ODI #984633
Mileage unknown · May 31, 1995
Electrical SystemEngine And Engine CoolingExterior Lighting
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.
Consequence & remedy
Consequence: THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.
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.
Consequence & remedy
Consequence: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
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
5
PE02076 · Luggage Compartment Door Drops Abruptly
Opened Oct 10, 2002 · Closed Mar 10, 2003
Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate:support Device/strut
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.
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
RQ98012 · Transfer Cases And Rear Driveshaft
Opened Jul 31, 1998 · Closed Jan 7, 1999
Status: closed (inferred from source dates) · Power Train:transfer Case (4-WHEEL Drive)
There is no summary currently available
EA98016 · Fuel Sender Assembly Fires
Opened Jul 14, 1998 · Closed Feb 12, 1999
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
Additional source detail variants (2)
Vehicle Speed Control:linkages
There is no summary currently available
Vehicle Speed Control:linkages
There is no summary currently available
PE98010 · Fuel Sender Assembly Fires
Opened Feb 13, 1998 · Closed Jul 14, 1998
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
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.
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