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1996 Ford Aerostar

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 1996 Ford Aerostar do not stand out strongly from the model-year median of 135.5.

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How this year compares

Owner complaints by model year

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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: 14 of 104 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.

  • Wheels. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 16 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports4 fire reports6 injury reports

Tires complaints

5 reports
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99,500 miles · Jun 3, 2004
Tires

WHILE DRIVING 70 MPH, THE REAR DRIVER SIDE TIRE TREAD SEPARATED. THE CONSUMER MANAGED TO PULL OVER TO CHANGE TIRE. THE DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. PLEASE PROVIDE MORE INFORMATION. SIZE#21570R14 DOT#HYHY4FA229. *NM

NHTSA ODI #10075653

247,502 miles · Aug 20, 2003
Tires

I NOTICED A "PINHOLE" ON MY VIPER GT TIRES, CONTACTED THE DEALER WHERE I PURCHASED THEM, THEY TOLD ME THAT THEY WERE NOT ON A RECALL LIST BUT WOULD REPLACE THEM FOR A "DIFFERENCE" COST. I RESEARCHED THE INTERNET AND DISCOVERED THAT 1-2 YEARS EARLIER COOPER (THE MANUFACTURER) GAD A RECALL ON A SIMILAR ISSUE. THE DOT NUMBER OF THE…

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I NOTICED A "PINHOLE" ON MY VIPER GT TIRES, CONTACTED THE DEALER WHERE I PURCHASED THEM, THEY TOLD ME THAT THEY WERE NOT ON A RECALL LIST BUT WOULD REPLACE THEM FOR A "DIFFERENCE" COST. I RESEARCHED THE INTERNET AND DISCOVERED THAT 1-2 YEARS EARLIER COOPER (THE MANUFACTURER) GAD A RECALL ON A SIMILAR ISSUE. THE DOT NUMBER OF THE TIRES THAT HAD ON MY VAN WERE AS FOLLOWS: 30 HY UDN2802 - THIS TIRE HAD NO NOTICABLE PINHIOLE 30 HY UDN2401 - PINHOLE WITH VISIBLE WIRE THREADS VISIBLE 30 HY UDN2402 - PINHOLE WITH VISIBLE WIRE THREADS VISIBLE 30 HY UDN3001 - PINHOLE BUT NO VISIBLE WIRES SHOWING YET. *AK

NHTSA ODI #10033205

81,908 miles · Aug 15, 2003
Tires

WHILE DRIVING, THE TIRE EXPERIENCED TREAD SEPARATION. *AK *JB

NHTSA ODI #10031229

Mileage unknown · Jul 20, 2002
Tires

THESE 2 TIRE FAILURES OCCURRED UNDER NORMAL DRIVING CIRUCUMSTANCES ON A VEHICLE THAT IS REGULARLY MAINTAINED AT THE FIRESTONE SERVICE CENTER THAT INSTALLED THE TIRES. FIRESTONE HAS DENIED CLAIM OF VEHICLE REPAIR FROM THE TIRE SEPARATION INCIDENT ON JUNE 16, 2002, SAYING THE 'TIRE WAS IMPROPERLY INFLATED FOR AN UNDETERMINED TIM…

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THESE 2 TIRE FAILURES OCCURRED UNDER NORMAL DRIVING CIRUCUMSTANCES ON A VEHICLE THAT IS REGULARLY MAINTAINED AT THE FIRESTONE SERVICE CENTER THAT INSTALLED THE TIRES. FIRESTONE HAS DENIED CLAIM OF VEHICLE REPAIR FROM THE TIRE SEPARATION INCIDENT ON JUNE 16, 2002, SAYING THE 'TIRE WAS IMPROPERLY INFLATED FOR AN UNDETERMINED TIME PERIOD'. THEIR OWN PEOPLE INSPECTED THE TIRES 40 DAYS PRIOR, THE TIME OF THE 1ST TIRE SEPARATION, CLAIMING TIRES TO BE WORTHY, PROPERLY INFLATED ETC. WE FIRMLY BELIEVE THAT AN INVESTIGATION INTO THESE TIRES MUST HAPPEN, IF IT ISNT ALREADY UNDERWAY. THIS WAS A POTENTIALLY DANGEROUS SITUATION THAT FORTUNATELY DID NOT END TRAGICALLY, OTHER THAN DOLLARS SPENT OUT OF OUR POCKET. PLEASE TAKE SERIOUS NOTE TO OUR CIRCUMSTANCE, IT CAN NOT BE COMMON OF TIRES THAT 2 WOULD SEPARATE IN 40 DAYS ON A REGULARLY MAINTAINED VEHICLE ON A CLEAR HIGHWAY AND SPEEDS UNDER NORMAL HIGHWAY SPEED LIMITS. AFTER THE FIRST TIRE FAILURE, THE SERVICE CENTER MANAGER STATED THAT THE 'TIRE HAD SEPARATED AND FAILED'. AFTER THE SECOND SEPARATION, THE SAME MANAGER HAD THE SAME STATEMENT FOR THE SECOND TIRE. THEY ULTIMATELY WERE WILLING TO REPLACE ALL 4 TIRES WITH A BRIDGESTONE PRODUCT, FOR US, THAT WAS UNACCEPTABLE, WE CHOOSE TO TAKE OUR BUSINESS ELSEWHERE (CLEARLY, NOT AN ISSUE FOR THE NHTSA). THOUGH, WHAT IS OF GREAT CONCERN TO US IS THE LACK OF URGENCY ON THE PART OF LOCAL FIRESTONE AND CORPORATE FIRESTONE THAT THERE COULD POTENTIALLY BE A SERIOUS PROBLEM WITH A PRODUCT THEY SELL.THANK YOU IN ADVANCE FOR YOUR TIME, YOUR PROMPT RESPONSE, AND YOUR CONSIDERATION.*AK

NHTSA ODI #764493

Mileage unknown · May 4, 2001
Tires

COMPONENT #1: RIGHT REAR PASSENGER TIRE....I HEARD A THUMPING NOISE AND PULLED OVER TO CHECK.I FOUND THAT THE TIRE WAS FAILING ON THE INSIDE CAUSING A VERY LARGE BUBBLING EFFECT TO OCCUR WHICH IN TURN WAS BREAKING THE INNER TIRE WIRES AND PUSHING THE TREAD OUT FROM THE BODY OF THE TIRE. WHEN I TOOK IT INTO TIRE KINGDOM, SO. US…

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COMPONENT #1: RIGHT REAR PASSENGER TIRE....I HEARD A THUMPING NOISE AND PULLED OVER TO CHECK.I FOUND THAT THE TIRE WAS FAILING ON THE INSIDE CAUSING A VERY LARGE BUBBLING EFFECT TO OCCUR WHICH IN TURN WAS BREAKING THE INNER TIRE WIRES AND PUSHING THE TREAD OUT FROM THE BODY OF THE TIRE. WHEN I TOOK IT INTO TIRE KINGDOM, SO. US #1, FT. PIERCE, I WAS TOLD THAT IT WAS CAUSE FROM UNEVEN OUTTER WEAR---NOT!---AND THAT SINCE I HAD BOIUGHT THE LOWER PRICED TIRE THAT THAT WAS ALL I COULD EXPECT. I HAD TO BUT A REPLACEMENT TIRE. THE SAME THING HAPPENED ON 4/17/2001 TO THE DRIVER FRONT TIRE. PLEASE BEAR IN MIND THAT ALL FOUR OF THE TIRES ON THIS VECHICLE WERE BOUT AT THE DAME TIME AND EXPERIENCE THE SAME WEAR. I AM CONCERNED THAT THIS IS A SERIOUS TYPE OF DEFECT IN THE SAME VEIN AS THE FIRESTONE FAILURES AND THAT HAD I BEEN ON THE HIGHWAY I AND ANY PASSENGER COULD HAVE BEEN KILLED. THE INSULT TO INJURT WAS THAT "I SHOULD EXPECT THIS KIND OF FAILURE SINCE I ROUTINELY DO NOT PURCHASE ANY TIRE OTHER THAT THE LOWER MODERATE PRICED ONES. IT IS MY CONTENTION THAT NORMAL WEAR HAS TO DO W/TREAD WEAR, NOT INTERNAL FAILURE CAUSING DAMAGE.*AK

NHTSA ODI #744937

Official recalls

4

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.

96V161000 · Equipment:other:labels

Aug 29, 1996

THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence & remedy

Consequence: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .

Remedy: OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.

96V070000 · Latches/locks/linkages:doors:latch

Apr 22, 1996

WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."

Consequence & remedy

Consequence: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.

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

2

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