FRONT COIL SPRINGS SNAPPED, HAD TO REPLACED WITH READING SPRING WORKS, THEY HAD TO SEND THE SPECKS TO CHICAGO. MY FORD AERO STAR 4 WHEEL DRIVE & 4.0 V6 IS NOT AVAILABLE FROM AFTER MARKET. THE ONLY OPTION IS TO BUY NEW OR USED FORD SPRINGS WHICH ARE MADE IN CHINA. THE LOCAL FORD DEALER ADMITS REPLACING COIL & LEAF SPRINGS ON SEVE…
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FRONT COIL SPRINGS SNAPPED, HAD TO REPLACED WITH READING SPRING WORKS, THEY HAD TO SEND THE SPECKS TO CHICAGO. MY FORD AERO STAR 4 WHEEL DRIVE & 4.0 V6 IS NOT AVAILABLE FROM AFTER MARKET. THE ONLY OPTION IS TO BUY NEW OR USED FORD SPRINGS WHICH ARE MADE IN CHINA. THE LOCAL FORD DEALER ADMITS REPLACING COIL & LEAF SPRINGS ON SEVERAL MODELS. MIDAS WAS SO BUSY REPLACING FORD SPRINGS, THEY COULD NOT SET UP AN APPOINTMENT TO INSTALL SPRINGS EVEN IF I HAD THE SPRINGS. *TR
NHTSA ODI #10217895
Mileage unknown · Jul 8, 2003
Power Train
CONSUMER STATES THAT THE GEAR SHIFT CAN BE PUSHED DOWN WITHOUT APPLYING THE BRAKE. DEALER NOTIFIED.*AK
NHTSA ODI #10026717
Mileage unknown · May 5, 2003
Power Train
AUTOMATIC TRANSMISSION FAILURE - TRANSMISSION FALLS OUT OF GEAR. *JB
NHTSA ODI #10017023
Mileage unknown · May 23, 2002
Power Train
THE TRANFER CASE HEATED UP AND SEPARATED FROM THE TRANSMISSION IN THE PROCESS THE TRANSMSSION WAS CRACKED AND REPLACED, THREE TIMES BY THE MANUFACTURER.*JB THE TRANSFER CASE WAS RECALLED (97V-204) BY THE MANUFACTURER AFTER THE TRANSMISSION HAD FAILED THREE TIMES. *YH
NHTSA ODI #8010438
Mileage unknown · Nov 30, 2001
Power Train
REAR PASSENGER SIDE WHEEL CAME OFF WHILE CONSUMER WAS DRIVING UP A SLIGHT INCLINE. DEALER HAS BEEN CONTACTED, AND INFORMED CONSUMER THAT AXLES WERE DEFFECTIVE. PLEASE PROVIDE FURTHER DETAILS. *AK
NHTSA ODI #899755
Mileage unknown · Nov 26, 2001
Power TrainInjury
AFTER CONSUMER PARKED VEHICLE AND TOOK KEY OUT OF IGNITION, WHILE GETTING OUT OF VEHICLE, IT STARTED ROLLING BACKWARD, CONSUMER WAS CAUGHT BY DOOR, BRUISED BADLY. VEHICLE WAS STOPPED BY A TREE. SINCE IT ROLLED VERY SLOWLY THERE WAS NO DAMAGE. VEHICLE NOT TAKEN TO DEALER YET. *AK *SLC
NHTSA ODI #899421
Mileage unknown · Jul 1, 2001
Power Train
WHILE DRIVING IN THE SMOKY MOUNTAINS IN NC THE TRANSMISSION OVERHEATED AND POURED OUT TRANSMISSION FLUID. THE VAN BEGAN TO SMOKE AND I PULLED OVER IN A DANGEROUS PLACE. I DECIDED TO TURN AROUND (ALSO IN DANGEROUS PLACE) I WENT BACK TO CHEROKEE, NC AND A MECHANIC SAID THIS WAS A COMMON PROBLEM FOR AREOSTARS. HE SAID MANY PEOPLE G…
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WHILE DRIVING IN THE SMOKY MOUNTAINS IN NC THE TRANSMISSION OVERHEATED AND POURED OUT TRANSMISSION FLUID. THE VAN BEGAN TO SMOKE AND I PULLED OVER IN A DANGEROUS PLACE. I DECIDED TO TURN AROUND (ALSO IN DANGEROUS PLACE) I WENT BACK TO CHEROKEE, NC AND A MECHANIC SAID THIS WAS A COMMON PROBLEM FOR AREOSTARS. HE SAID MANY PEOPLE GET RIPPED OFF BY UNTRUSTWORTHY MECHANICS. WHILE TRAVELING OVER THE MOUNTAINS WE SAW THREE OTHER AREOSTARS WITH THE SAME PROBLEM. TWO WERE BEING TOWED BY WRECKERS. AREOSTAR OWNERS NEED TO BE NOTIFIED OF THIS PROBLEM. THAT THE TRANSMISSION WILL OVERHEAT UNDER A LOAD AND TRANSMISSION FLUID WILL BE LOST. WE WERE VERY UPSET BY THIS AND OUR VACATION WAS RUINED. BUT BECAUSE WE FOUND A GOOD MECHANIC WE WERE NOT RIPPED OFF. I CANNOT SAY THE SAME ABOUT THE OTHER VANS THAT WE SAW BEING TOWED FROM THE MOUNTAIN AND WE WERE ONLY THERE FOR A COUPLE OF HOURS AND SAW THREE OTHERS IN TROUBLE.*AK
NHTSA ODI #747646
Mileage unknown · Apr 22, 2001
Engine And Engine CoolingFuel System, GasolinePower TrainFireInjury
MY CLIENTS, THE FREDERICK FAMILY (FATHER, MOTHER AND 3-YR-OLD DAUGHTER) SUSTAINED THIRD DEGREE BURNS WHEN THEIR 1994 FORD AEROSTAR VAN SPONTANEOUSLY CAUGHT FIRE WHILE TRAVELLING ON I-40 NEAR NEEDLES, CALIFORNIA. FIRE WAS THE RESULT OF THE TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT, THEREBY FAILING THE DRIVE SHAFT WHICH STR…
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MY CLIENTS, THE FREDERICK FAMILY (FATHER, MOTHER AND 3-YR-OLD DAUGHTER) SUSTAINED THIRD DEGREE BURNS WHEN THEIR 1994 FORD AEROSTAR VAN SPONTANEOUSLY CAUGHT FIRE WHILE TRAVELLING ON I-40 NEAR NEEDLES, CALIFORNIA. FIRE WAS THE RESULT OF THE TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT, THEREBY FAILING THE DRIVE SHAFT WHICH STRUCK THE PAVEMENT, THEN RICHOCHETED INTO THE FUEL TANK AND PIERCED THE TANK, ALLOWING RAW FUEL TO ESCAPE AND IGNITE, PROBABLY FROM THE CATALYTIC CONVERTER OR SPARKS FROM THE DRIVE SHAFT STRIKING THE PAVEMENT. THIS CASE IS IN LITIGATION IN UNITED STATES DISTRICT COURT IN LAS VEGAS, NEVADA, BEING CASE NO. CV-S-00-0444-KTD-RLH. PETER CHASE NEUMANN, ATTORNEY FOR PLAINTIFFS, 136 RIDGE STREET, RENO, NV 89501. 775-786-3750.
NHTSA ODI #744382
Mileage unknown · Jan 9, 2001
Electrical SystemEngine And Engine CoolingEquipment
REMINGTON TIRES (P205/75R14) WERE REPLACED. *SLC
NHTSA ODI #558844
Mileage unknown · Oct 16, 2000
Power Train
THE SPEEDOMETER CLUSTER QUIT WORKING PAST 100,000 MILES, THERE WAS NO WAY TO TELL THE VEHICLES SPEED. NLM
VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.
Consequence & remedy
Consequence: HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.
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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