IllustrationWHILE DRIVING VEHICLE LOST CONTROL. TOOK VEHICLE TO INDEPENDENT REPAIR SHOP, AND MECHANIC INDICATED THAT THIS VEHICLE WAS ON RECALL CONCERNING TRANSFER CASE PROBLEM. ALSO, HAD BRAKE SYSTEM PROBLEM. *AK
1993 Ford Aerostar
Owner reports · Recalls · Investigations
More warning signs than most Aerostar years
Owner complaints for the 1993 Ford Aerostar are substantially higher than 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: 18 of 374 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 99 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 68 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
37 crash reports38 fire reports28 injury reports
Service Brakes, Hydraulic complaints
57 reportsCANCELLATION OF GENERAL RECALL TSB94B38 WHICH HAD TO DO WITH ABS GENERAL RECALL WHICH FORD SAYS IS NOW EXPIRED. MY REAR BRAKES LOCKUP FIRST THING IN THE MORNING, AND SOMETIMES DURING THE DAY, SOMETIMES I GET A ABS LIGHT.*AK
THERE IS A FITTING FOR THE BRAKE LINE, MOUNTED TO A BRACKET BEHIND THE RIGHT FRONT WHEEL. THE RUBBER LINE POPPED OFF THE PIN THAT HOLDS IT IN PLACE, DUMPING THE BREAK FLUID AND LEAVING ME WITH NO BRAKES. I HAD HIT THE BREAKS TO AVOID HITTING A DOG. FORTUNATLY THERE WAS NO IMMEDIATE DANGER THAT WOULD CAUSE AN ACCIDENT. I WAS ABLE…
Read full complaint
THERE IS A FITTING FOR THE BRAKE LINE, MOUNTED TO A BRACKET BEHIND THE RIGHT FRONT WHEEL. THE RUBBER LINE POPPED OFF THE PIN THAT HOLDS IT IN PLACE, DUMPING THE BREAK FLUID AND LEAVING ME WITH NO BRAKES. I HAD HIT THE BREAKS TO AVOID HITTING A DOG. FORTUNATLY THERE WAS NO IMMEDIATE DANGER THAT WOULD CAUSE AN ACCIDENT. I WAS ABLE TO STEER AROUND THE DOG. IF THERE HAD BEEN A CAR THAT PULLED OUT I WOULDN'T HAVE HAD ANY CHANCE TO STOP. THIS IS THE SECONT TIME THIS HAS HAPPENED. LAST TIME I WAS TAKING THE TRANSMISSION OUT OF PARK ON AN INCLINE WHEN THE OTHER SIDE POPPED. I FEEL THIS IS A SERIOUS PROBLEM.*AK
FRONT BRAKES HAD LOCKED UP WHEN APPLIED AND THEN BURNED ROTORS. COULD FEEL VIBRATION IN VEHICLE WHEN THIS HAPPENED. TOOK VEHICLE TO DEALER, AND MECHANIC INDICATED WHEEL CYLINDERS WERE NOT MADE OF METAL. PISTONS HAD EXPANDED, AND WERE NOT MOVING BACK & FORTH FREELY. BRAKE SYSTEM WAS REPLACED.*AK *SLC
ADD: RIGHT REAR BRAKE DRUM CONTACTING BACK PLATE ON INNER LIP. BRAKE SHOE PAD CONTACTING INNER BRAKEDRUM RADIUS 10/95
AIR CONDITIONER FAILED. *SLC
WHILE DRIVING VEHICLE IDLED, AND THEN SUDDENLY ACCELERATED, CAUSING A CRASH. BRAKES DID NOT SLOW THE VEHICLE, BUT CAUSED VEHICLE TO SKID. PLEASE PROVIDE FURTHER INFORMATION. *AK
VEHICLE EXPERIENCED BRAKE LOSS. PEDAL WENT TO THE FLOOR WHILE PULLING INTO A PARKING LOTS, CAUSING VEHICLE TO HIT A STEEL POLE. DEALER/MANUFACTURER WERE NOT CONTACTED AT THIS TIME. *AK
THE REPLACEMENT DISCS ARE DIFFERENT LEFT/RIGHT BUT NETITHER THE PART OR ITS PART NUMBER/PACKAGE TELLS THE INSTALLER WHICH IS WHICH. THIS COULD LEAD TO OVERHEATING. *AK
WHILE ATTEMPTING TO PUT THE VEHICLE IN REVERSE AND BACK OUT OF A PARKING SPACE, BRAKE LINE CRACKED AND ALL THE BRAKE FLUID CAME OUT OF THE VEHICLE. *AK
Official recalls
299V029000 · Electrical System:ignition:switch
Feb 9, 1999
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.
97V204000 · Power Train:transfer Case (4-WHEEL Drive)
Nov 13, 1997
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
5PE02076 · 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.