Electrical System. Review the 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Air Bags. Review the 44 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 42 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

22 crash reports27 fire reports23 injury reports

What owners actually said

257 reports

Mileage unknown · Nov 1, 1999

Air BagsElectrical SystemVehicle Speed Control

AIR BAG LIGHT BLINKING ON AND OFF. *ET

NHTSA ODI #784262

Mileage unknown · Oct 15, 1999

Electrical SystemFuel System, Gasoline

ELCTRICAL SYSTEM WIRING HARNESS MADE ALL THE DASH LIGHTS SHUT OFF, THEN BACK ON. BUT, MOST OF THE TIME THEY STAYED OFF. DEALER SAID ONLY ONE INJECTOR WAS BAD. BUT, WHEN CONSUMER TOOK VEHICLE TO DEALER, THEY REPLACED ALL OF THEM. *AK

NHTSA ODI #850896

Mileage unknown · Sep 20, 1999

Air Bags

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AIR BAG MALFUNCTION LIGHT, AND HORN MALFUNCTION, HAPPENED AT SAME TIME. DEALER TOLD ME THAT A COMMON CIRCUIT WAS MORE THAN LIKELY THE PROBLEM. TOLD ME THAT AIR BAG, AND HORN WOULD NOT WORK UNTIL STEERING COLUMN REMOVED, AND CIRCUIT FIXED. CAR WILL NOT PASS INSPECTION WITH HORN NOT WORKING. FEEL UNSAFE WITH AIR BAG NOT WORKING. TOLD THAT AIR BAG WARRANTY RAN OUT AT 50,000 MILES. WHEN DEALER ASKED FOR POSSIBLE "GOOD WILL" REPAIR, TOLD NO! FEEL THAT ONLY WAY TO GET ANYWHERE IS THROUGH NHTSA, SINCE BOTH PROBLEMS ARE SAFETY RELATED. THANK YOU.

NHTSA ODI #711638

Mileage unknown · Sep 15, 1999

Electrical SystemFire

WHILE THE VAN WAS PARKED THERE WAS AN ELECTRICAL FIRE THAT STARTED UNDER THE HOOD ON THE DRIVER'S SIDE. THIS HAPPENED ABOUT 5 MINUTES AFTER THE VAN WAS DRIVEN. FIRE WAS PUT OUT BY THE FIRE DEPARTMENT. THE VAN WAS TOTALLED. *AK

NHTSA ODI #847803

Mileage unknown · Sep 15, 1999

Power Train

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IN MARCH OF 1995 I TOOK CUSTODY OF MY THREE NIECES, DUE TO THEIR MOTHER'S ADDICTION TO METH. AT THAT POINT WE OWNED A FORD EXCORT, WHICH WE TRADED IN ON THE FORD AEROSTAR IN MAY OF THAT YEAR, WITH APPROXIMATELY 18,000 MILES. WHEN THE VAN REACHED APPROX. 55,000 MILES MY WIFE WAS DRIVING IN PHOENIX AND THE TRANSFER CASE WENT OUT, WHILE SHE WAS DRIVING AROUND 35 MPH. SINCE THE COMPONENT WAS UNDER WARRANTY PIONEER FORD REPLACED THE COMPONENT, AND THIS ONLY TOOK THEM 5 TO 6 WEEKS. IN AUGUST OF 1998 THE TRANSFER CASE WENT OUT AGAIN, WITH APPROX. 108,000 MILES, AND THIS TIME THE FORD DEALER IN BLYTHE REPLACED THE COMPONENT AND DRIVE SHAFT UNDER A RECALL NOTICE. LESS THAN 12 MONTHS LATER, ON AUGUST 13, 1999, THE TRANSFER CASE WENT OUT AGAIN. WE TOOK IT TO FIRESTONE AND THEY THOUGHT THE PROBLEM WAS A CV JOINT, WHICH THEY REPLACED. THE PROBLEM CONTINUED AND THEY SENT US TO BOB TURNER'S FORD IN ALBUQUERQUE, NM. EVEN THOUGH FIRESTONE HAD INFORMED THEM OF THE PROBLEM, THEY PROCEEDED TO SAY IT WAS BAD CV JOINTS (INCLUDING THE NEW ONE) AND REPLACED THESE AND OTHER MISC. AT A COST OF $900.00 AND THE PROBLEM STILL EXIST. THEY NOW INFORM ME THAT IT IS THE TRANSFER CASE AND IT WILL COST $2500.00 TO FIX. I CONTACTED FORD ABOUT THIS PROBLEM AND THE FACT THAT 3 TRANSFER CASES IN 3 YEARS IS NOT ACCEPTABLE, BUT THEY REFUSE TO HELP IN THIS MATTER. WHEN I TALKED TO A PERSON AT CUSTOMER SERVICE, HE SAID FORD WOULD REPLACE THE PART IF DEFECTIVE, I THEN ASKED PAUL AT BOB TURNER'S FORD IF THE PART WAS DEFECTIVE, AND HE SAID "YES" BUT FORD NOW SAYS THAT SINCE IT HAS OVER 12,000 MILES THEY WILL DO NOTHING. I DO NOT BELIEVE THAT A VEHICLE THAT HAS NEVER BEEN IN 4-WHEEL DRIVE SHOULD HAVE GONE THROUGH 3 TRANSFER CASES IN 3 YEARS, THIS IS A DEFECT TO ME AND THE MANY MECHANICS THAT I HAVE TALKED TO. PLEASE LOOK INTO THIS MATTER AND LET ME KNOW WHAT CAN BE DONE, FOR I CAN NOT BE THE ONLY PERSON IN THIS SITUATION.

NHTSA ODI #711394

Mileage unknown · Sep 8, 1999

Engine And Engine Cooling

THE ENGINE HAD STARTED TO OVERHEAT. HAD HEARD A TICKING NOISE PRIOR TO VEHICLE SHUTTING DOWN. HAD VEHICLE TOWED TO DEALER. WAS INFORMED BY MECHANIC ENGINE LOST COMPRESSOR PART & NEEDED TO BE REPLACED. *AK

NHTSA ODI #847138

Mileage unknown · Sep 8, 1999

Suspension

WELD CAME APART ON RIGHT SWAY BAR ASSEMBLY, CAUSING IT TO TEAR THROUGH ANY PARTS SURROUNDING IT. *AK

NHTSA ODI #847072

Mileage unknown · Aug 19, 1999

Structure

TAILGATE SUPPORT ARM BROKE. WHEN CONSUMER WENT TO LIFT THE TAILGATE IT COLLAPSED. DEALER HAS NOT BEEN CONTACTED. *AK

NHTSA ODI #845400

Mileage unknown · Aug 12, 1999

Seat Belts

THE RELEASE BUTTON ON THE SEAT BELT BUCKLE IN THE REAR MIDDLE SEAT WOULD NOT RELEASE THE SEAT BELT. OWNER USED PLIERS TO PULL THE BELT OUT OF THE BUCKLE. PLEASE PROVIDE ANY FURTHER DETAILS. *YC

NHTSA ODI #838790

Mileage unknown · Aug 2, 1999

Electrical System

PRIOR TO RECALL NOTICE FAILURE OF RECALL COMPONENT CAUSED THE ELECTRIC CIRCUIT TO OVER LOAD/SHORT AND DAMAGE TO THE ELECTRIC CONNECTIONS OF AIR BAG,HORN,TRANSMISSION AND DOOR ALARM ( 99V029). YH

NHTSA ODI #547693

Official recalls

99V028000 · Electrical System:wiring:front Underhood

Feb 9, 1999

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.

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

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.