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: 15 of 257 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 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 · 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 · Jun 27, 2001
Electrical SystemFire
VHEHICLE CAUGHT FIRE NEAR CENTER OF MOTOR BEHIND WHERE YOU PUT IN THE OIL. VEHICLE WAS TAKEN TO LOCAL FORD DEALER FOR RECALL ON THE ACCESSORY POWER CIRCUIT. I RECEIVED A LETTER IN THE MAIL ABOUT THE SWITCH RECALL. THE 94-95 MODELS WHERE ALSO RECALLED DUE AN ELECTRICAL SHORT OUT AT FUEL PUMP RESULTING IN POWER LOSS AND FIRE.…
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VHEHICLE CAUGHT FIRE NEAR CENTER OF MOTOR BEHIND WHERE YOU PUT IN THE OIL. VEHICLE WAS TAKEN TO LOCAL FORD DEALER FOR RECALL ON THE ACCESSORY POWER CIRCUIT. I RECEIVED A LETTER IN THE MAIL ABOUT THE SWITCH RECALL. THE 94-95 MODELS WHERE ALSO RECALLED DUE AN ELECTRICAL SHORT OUT AT FUEL PUMP RESULTING IN POWER LOSS AND FIRE. I BELIVE THIS TO BE WHAT HAPPENED TO MY VAN.I WAS NOT NOTIFIED OF THIS RECALL, NIETHER WAS I INFORMED OF IT WHAN I TOOK THE VAN IN FOR THE OTHER RECALL ON THE SWITCH. CAN YOU TELL ME WHAT TO DO FROM HERE? SHOULD I GO TO THE LOCAL FORD DEALER? *AK
NHTSA ODI #747478
Mileage unknown · Jun 25, 2001
Electrical System
NO SUMMARY LISTED FOR ABOV EVEHICLE. *AK
NHTSA ODI #747364
Mileage unknown · May 23, 2001
Engine And Engine Cooling
VEHICLE EXPERIENCING PROBLEM WITH LOSS OF COOLANT AND OVERHEATING WHILE DRIVING. INDEPENDENT MECHANIC INFORMED OF A HEAD GASKET FAILURE. VEHICLE WAS NOT COVERED UNDER MANUFACTURER'S EXTENDED WARRANTY. FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK
NHTSA ODI #889015
Mileage unknown · May 8, 2001
Latches/locks/linkages
SLIDING DOOR WOULD JAM AFTER BEING CLOSED. CANNOT USE KEY TO OPEN. SOMETIMES WHILE DRIVING, EITHER UP A HILL OR HITTING A BUMP, SLIDING DOOR WOULD OPEN WITHOUT WARNING. HAVE TAKEN TO DEALERSHIP, MECHANIC GAVE AN ESTIMATE OF COST OF NEW DOOR REPLACEMENT.*AK *JB
NHTSA ODI #887759
Mileage unknown · May 1, 2001
Air Bags
THIS VEHICLE HAS NEVER BEEN IN AN ACCIDENT THAT I AM AWARE OF AND OVER A YEAR AGO WHILE DRIVING MY AIR BAG LIGHT POPED ON. WHEN I GOT HOME I CALLED OUR LOCAL FORD GARAGE & THEY INFORMED ME THAT THE AIR BAG NO LONGER WAS WORKING. I FEEL IF YOU BUY THE VEHICLE WITH THE AIR BAG YOU EXSPECT IT TO BE THERE IN CASE OF AN ACCIDENT. WHA…
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THIS VEHICLE HAS NEVER BEEN IN AN ACCIDENT THAT I AM AWARE OF AND OVER A YEAR AGO WHILE DRIVING MY AIR BAG LIGHT POPED ON. WHEN I GOT HOME I CALLED OUR LOCAL FORD GARAGE & THEY INFORMED ME THAT THE AIR BAG NO LONGER WAS WORKING. I FEEL IF YOU BUY THE VEHICLE WITH THE AIR BAG YOU EXSPECT IT TO BE THERE IN CASE OF AN ACCIDENT. WHAT IS THE POINT IN HAVING ONE IF IT CANNOT LIVE UP TO THE LIFE OF YOUR VEHICLE. THE PART IS ONLY 150.00 BUT I REFUSE TO PAY FOR SOMETHING TO BE FIXED IF IT WAS NEVER DEPLOYED IN THE FIRST PLACE. THIS IS SUPPOSE TO BE A SAFTY FEATURE BUT IT IS NOT VERY SAFE IF IT NO LONGER WORKS. *AK
NHTSA ODI #744794
Mileage unknown · Apr 25, 2001
Engine And Engine Cooling
WHILE DRIVING ON INTERSTATE VEHICLE STARTED TO LOOSE POWER AND THEN CEASED TO FUNCTION ALTOGETHER, VEHICLE WAS TOWED INTO DEARLERSHIP AND CONSUMER WAS ADVISED THAT THE ENGINE BLOCK WAS CRACKED AND THAT THE ANTI-FREEZE WAS GETTING INTO THE ENGINE, CONSUMER PURCHASED A REBUILT ENGINE. *JB
NHTSA ODI #560922
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 · Apr 18, 2001
Electrical System
VEHICLE IS STALLING AT ANY SPEED, AND ANY TIME. DEALER STATED IGNITION MODULE NEEDED TO BE REPLACED. *AK
NHTSA ODI #886189
Mileage unknown · Apr 2, 2001
Structure
WHILE DRIVING NEUMATIC ARM BROKE OFF OF TAIL BACK DOOR. PIECE BROKE OFF WITHOUT PRIOR WARNING.*AK *SLC
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.
1994 Ford Aerostar Problems, Complaints & Recalls | Skip That Year
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