IllustrationWIRING HARNESS UNDER DASH BURNED AND CAUGHT FIRE. NLM
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
What owners actually said
374 reportsVEHICLE EXPERIENCING ELECTRICAL FAILURE/SHORTS RESULTING IN FAILURE OF SEVERAL COMPONENTS, PRIOR TO RECALL NOTICE (99V-029). *YC
WHILE DRIVING AT 40 MPH THERE WERE NO BRAKE LIGHTS. CONSUMER COULDN'T GET THE VEHICLE OUT OF PARK, AND THE BRAKE FUSE BLEW OUT. DEALER COULDN'T DETERMINE THE CAUSE OF THE PROBLEM. *AK
WHILE DRIVING SOUTHBOUND ON I-65 IN NASHVILLE, MY HUSBAND AND I BEGAN TO SMELL SMOKE AND THEN SUDDENLY SMOKE BEGAN POURING FROM THE STEERING COLUMN OF OUR 1993 FORD AEROSTAR. AFTER PULLING OVER ON THE SIDE OF THE ROAD, I REMOVED OUR TWO SMALL CHILDREN WHILE MY HUSBAND ATTEMPTED TO SHUT OFF THE VAN. ALTHOUGH THE VAN WAS IN PARK…
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WHILE DRIVING SOUTHBOUND ON I-65 IN NASHVILLE, MY HUSBAND AND I BEGAN TO SMELL SMOKE AND THEN SUDDENLY SMOKE BEGAN POURING FROM THE STEERING COLUMN OF OUR 1993 FORD AEROSTAR. AFTER PULLING OVER ON THE SIDE OF THE ROAD, I REMOVED OUR TWO SMALL CHILDREN WHILE MY HUSBAND ATTEMPTED TO SHUT OFF THE VAN. ALTHOUGH THE VAN WAS IN PARK AND THE KEYS HAD BEEN REMOVED, THE VEHICLE STILL WAS ATTEMPTING TO CRANK ITSELF AND WOULD NOT STOP UNTIL WE PLACED THE VAN IN REVERSE (WITH THE PARKING BRAKE ON) AND UNHOOKED THE BATTERY. A MAN WHO STOPPED TO HELP US ALERTED US TO THE FACT THAT THERE HAD BEEN RECALLS ON THE INGNITION SWITCH OF SEVERAL FORD MODELS WHICH COULD POTENTIALLY CAUSE FIRES. THIS IS A VERY DANGEROUS SITUATION AND PEOPLE SHOULD BE ALERTED IN ORDER TO SAVE THEIR LIVES. *AK
IGNITION SWITCH AND WIRING FAILED SEVERAL TIMES CAUSING ELECTRICAL AND STARTER PROBLEMS DUE TO SPRING IN THE IGNITION SWITCH STICKING, FAILS IN HOT HUMID WEATHER CONDITIONS. MJS
WHEN VEHICLE STOPS AT A LIGHT ENGINE IDLES AND CAUSES THE VEHICLE TO ROCK. DEALER HAS SEEN VEHICLE 4 TO 5 TIMES, AND STILL THERE IS NO SOLUTION. *AK
RECEIVED RECALL NOTICE 99V029000 IN MAIL & CONTACTED DEALER. HAD REPAIRS DONE. HAD TO TAKE VEHICLE BACK AT LEAST 5 TIMES. MECHANIC HAD UNHOOKED WIRES DUE TO CHECK ENGINE LIGHT KEPT COMING ON. STARTED HAVING OTHER ELECTRICAL PROBLEMS AFTER IGNITION SWITCH WAS REPAIRED (HEAD LAMP, DASHBOARD, DOME LIGHT & WINDOWS). *AK
RECALL 97V204000, THE TRANSFER CASE RECALL WAS REPAIRED, AND VEHICLE CONTINUES TO SHAKE AT HIGHWAY SPEED WHICH MAY CAUSE LOSS OF CONTROL. THE PROBLEM STARTED AFTER RECALL REPAIRS WERE DONE. PLEASE PROVIDE FURTHER INFORMATION. *AK
VEHICLE IS DENIED RECALL WORK DUE TO LACK OF PARTS (99V-029). MJS
AFTER CAMPAIGN 99V029000 WAS COMPLETED, I STILL HAD MAJOR ELECTRICAL ISSUES, INCLUDING: THE TURN SIGNALS NOT WORKING, INTERIOR LIGHT ANOMOLIES AND BOGUS ABS BRAKE SYSTEM WARNINGS FROM THE DASHBOARD LIGHTS. I REPLACED THE IGNITION SWITCH, THE ISSUES NO LONGER HAPPENED. I TOOK THE OLD SWITCH APART, IT DID HAVE THE ISSUES DESCRIB…
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AFTER CAMPAIGN 99V029000 WAS COMPLETED, I STILL HAD MAJOR ELECTRICAL ISSUES, INCLUDING: THE TURN SIGNALS NOT WORKING, INTERIOR LIGHT ANOMOLIES AND BOGUS ABS BRAKE SYSTEM WARNINGS FROM THE DASHBOARD LIGHTS. I REPLACED THE IGNITION SWITCH, THE ISSUES NO LONGER HAPPENED. I TOOK THE OLD SWITCH APART, IT DID HAVE THE ISSUES DESCRIBED IN NHTSA CAMPAIGN ID NUMBER: 99V029000. I FEEL THE CAMPAIGN WAS NOT COMPLETED CORRECTLY ON MY VEHICLE OR THERE IS A DEEPER ISSUE WITH THE IGNITION SWITCH. *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.