IllustrationTHE RIGHT FRONT WHEEL HAS FATIGUE CRACKS AROUND LUG NUT HOLES, CHP SUGGEST THAT WE CONTACT YOU, COULD BE A SAFETY ISSUE. *AK
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.
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: 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
Wheels complaints
23 reportsCASTING ON ALLOY WHEELS FAILED. OF SEVEN SPOKES ON WHEELS THREE HAD BROKEN. WHEELS WERE FALLING OFF THE AXLE. CONTACTED DEALER, AND FORD. FORD STATED DID NOT HAVE A RECALL ON ALLOY WHEELS. DEALER STATED WILL NOT REPLACE WHEELS UNLESS UNDER WARRANTY.*AK
BOTH FRONT WHEELS HAVE CRACKS IN THE FORD MANUFACTURED SPOOK WHEELS. FORD CONTACTED AND HAD NO EXPLANATION AND STATED IT IS MY PROBLEM. ONE FORD MECHANIC CONTACTED AND 4 WHEEL SHOPS CONTACTED AND STATED IT APPEARS TO BE A DESIGN FLAW. FORD REPRESENTATIVES HAD NO CONCERN CONCERNING SAFETY ISSUE. AS OF THIS DATE FORD WILL NOT A…
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BOTH FRONT WHEELS HAVE CRACKS IN THE FORD MANUFACTURED SPOOK WHEELS. FORD CONTACTED AND HAD NO EXPLANATION AND STATED IT IS MY PROBLEM. ONE FORD MECHANIC CONTACTED AND 4 WHEEL SHOPS CONTACTED AND STATED IT APPEARS TO BE A DESIGN FLAW. FORD REPRESENTATIVES HAD NO CONCERN CONCERNING SAFETY ISSUE. AS OF THIS DATE FORD WILL NOT ACCEPT ANY LIABLITY.
THREE OUT OF THE FOUR ALUMINIUM WHEELS ON THE AXLE OF THE CAR WHERE CRACKING UNTIL CONSUMER SWITCHED TO STEEL WHEELS AT HIS EXPENSE. DEALER WAS CONTACTED FOR REIMBURSEMENT, BUT REFUSED TO HONOR CONSUMERS REQUEST. *AK
1. THIS IS THE SECOND TIME THAT A WHEEL HAS DEVEOLPED A CRACK IN ONE OF ITS SPOKES. 2. A BOLT THAT HOLDS THE FRONTSIDE DRIVER SEATBACK IN AN UPRIGHT POSITION SHEARED OFF AND ALLOWED THE SEATBACK TO MOVE FREELY BACK AND FORTH.*AK
VEHICLE PARKED. OWNER NOTICED 3 WHEELS WERE CRACKED/BROKEN. TOOK VEHICLE TO DEALERSHIP TO HAVE WHEELS REPLACED. MECHANIC GAVE NO INDICATION OF WHAT CAUSED THE WHEELS TO BE CRACKED OR BROKEN. *AK *ML
WHILE DRIVING HEARD LOUD CLICKING NOISE FROM LEFT FRONT WHEEL, DISCOVERED CRACKS IN LEFT WHEEL, REPLACED THE WHEEL
WHEEL RIM BASE IS CRACKED. DEALER HAS BEEN CONTACTED. *AK
ALUMINIUM WHEELS HAVE A CRACK ON THE PASSENGERS SIDE WHEEL. *AK
DURING A BRAKE INSPECTION AT A TIRE STORE, IT WAS POINTED OUT THAT THE ORIGINAL ALUMINUM WHEELS WERE CRACKED. TWO OF THE LARGE SPOKES ON ONE WHEEL WERE CRACKED THROUGH. ONE OTHER WAS CRACKED BUT NOT ALL THE WAY THROUGH. I CALLED WENDLE FORD WHO HAD SOLD ME THE CAR. THEY SAID IT WASN'T A WARRANTY ITEM AND THEY HAD NEVER HEARD…
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DURING A BRAKE INSPECTION AT A TIRE STORE, IT WAS POINTED OUT THAT THE ORIGINAL ALUMINUM WHEELS WERE CRACKED. TWO OF THE LARGE SPOKES ON ONE WHEEL WERE CRACKED THROUGH. ONE OTHER WAS CRACKED BUT NOT ALL THE WAY THROUGH. I CALLED WENDLE FORD WHO HAD SOLD ME THE CAR. THEY SAID IT WASN'T A WARRANTY ITEM AND THEY HAD NEVER HEARD OF SUCH A FAILURE BEFORE. I TOOK THE CAR TO THE DEALER SHIP TO SHOW THEM THE CRACKED WHEELS. THEY THEN TOLD ME THAT I WAS THE SECOND PERSON TODAY (JANUARY 14, 2000) WHO HAD THE SAME PROBLEM WITH CRACKED WHEELS ON AN AEROSTAR, BUT IT STILL ISN'T A WARRANTY OR RECALL ITEM AND THEY WOULD BE HAPPY TO SELL ME NEW WHEELS. I DON'T BELIEVE WHEELS SHOULD BE CRACKING AFTER 3 YEARS. THIS IS ALSO A SAFETY CONCERN. LUCKILY THE PROBLEM WAS FOUND BEFORE IT CAUSED AN ACCIDENT. I HAVE TO BELIEVE THAT THIS PROBLEM IS WIDESPREAD IF 2 OF US IN ONE DAY AT ONE DEALERSHIP HAD THE PROBLEM. *AK
Official recalls
499V029000 · 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
2EA99002 · 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