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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.

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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

Structure complaints

23 reports
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Mileage unknown · Feb 9, 1999
StructureInjury

THE REAR STRUT THAT HOLDS UP THE TAILGATE EXPLODED AS THE TAILGATE WAS CLOSED AT THE GROCERY STORE. IT SENT A METAL PIECE SHOOTING THROUGH THE AIR, STRIKING ME IN THE HEAD, THEN COTINUING ON AND BREAKING THE FRONT WINDSHIELD IN 3 PLACES BEFORE FINALLY STOPPING. I WAS SENT TO THE DODTOR WITH A CONCUSSION, AND BLURRED VISION. I …

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THE REAR STRUT THAT HOLDS UP THE TAILGATE EXPLODED AS THE TAILGATE WAS CLOSED AT THE GROCERY STORE. IT SENT A METAL PIECE SHOOTING THROUGH THE AIR, STRIKING ME IN THE HEAD, THEN COTINUING ON AND BREAKING THE FRONT WINDSHIELD IN 3 PLACES BEFORE FINALLY STOPPING. I WAS SENT TO THE DODTOR WITH A CONCUSSION, AND BLURRED VISION. I LATER HAD TO RETURN TO THE EYE DOCTOR BECAUSE OF THE BLURRED VISION. THE VISION AND THE HEADACHES HAVE SINCE CLEARED UP. I WAS VERY LUCKY I DIDN'T LOSE AN EYE OR SOMEONE WASN'T KILLED. THE PIECE OF METAL IS ABOUT 12 INCHES LONG, AND IT STRUCK ME IN MY TEMPLE AREA. *AK

NHTSA ODI #703095

Mileage unknown · Oct 6, 1997
Engine And Engine CoolingEquipmentService Brakes, Hydraulic

BRAKE ROTORS FAILED.

NHTSA ODI #523539

Mileage unknown · Sep 3, 1997
Structure

ROOF SUPPORT RIBS CRACKED, ALLOWING WATER TO DRAIN.

NHTSA ODI #521666

Mileage unknown · Jul 22, 1997
Structure

THE SLIDING DOOR KEEPS COMING OFF THE TRACK. THE SERVICE DEPARTMENT AT THE FORD DEALER SAID THAT THE DOOR IS .25 INCH SMALLER THAN THE OTHER 93 VEHICLES. DOOR HAS BEEN REPAIRED 8 TIMES PRIOR TO TODAY.

NHTSA ODI #814695

Mileage unknown · May 9, 1997
Structure

STRUCTURE: WHEN OPENING THE LIFTGATE AND CLOSING, IT DOES NOT CATCH . THEREFORE THE LIFTGATE CAN COME LOOSE AT ANY TIME. *AK

NHTSA ODI #812130

Mileage unknown · Mar 20, 1997
Structure

CONSUMER'S CHILD CLOSED VEHICLE'S SIDE SLIDING DOOR AS HE WAS DOING SO, THE ROTOR CAME OFF THE TRACK AND THE DOOR STARTED TO FALL ON CHILD, NO INJURIES WERE SUSTAINED. *AK

NHTSA ODI #810252

Mileage unknown · Dec 30, 1996
Structure

THE CLEAR COAT OF PAINT JOB IS BEGINNING TO BREAK DOWN.

NHTSA ODI #513289

Mileage unknown · Dec 5, 1996
Structure

THE STUD HOLDING THE TOP END OF THE HATCHBACK STRUTS BROKE, CAUSING THE HATCHBACK TO CLOSE WHILE OPEN AND IN USE. PLEASE DESCRIBE DETAILS. *AK

NHTSA ODI #805917

Mileage unknown · Jul 25, 1996
Structure

WIDE SLIDING DOOR PANEL CREATES BLIND SPOT.*SD

NHTSA ODI #506629

Mileage unknown · Sep 27, 1995
StructureInjury

ONE OF THE PNEUMATIC BRACES THAT SUPPORT THE HATCH FAILED, CAUSING INJURY. *DSH

NHTSA ODI #488414

Official recalls

2

99V029000 · 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

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.