Model year record

1992 Ford Aerostar

3 recall campaigns on file for this model year. 439 owner complaints on file.

Recalls

Recall campaignNHTSA 99V094000

Power train: transfer case (4-wheel drive)

Component
Power train: transfer case (4-wheel drive)
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
10,951
Reported to NHTSA
1999-04-28
Owners notified
1999-06-17

Defect description

VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). 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.

Safety risk

THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.

Manufacturer remedy

DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

Recall campaignNHTSA 99V029000

Electrical system: ignition: switch

Component
Electrical system: ignition: switch
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
762,201
Reported to NHTSA
1999-02-09
Owners notified
1999-03-19

Defect description

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.

Safety risk

THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.

Manufacturer remedy

DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.

Recall campaignNHTSA 97V204000

Power train: transfer case (4-wheel drive)

Component
Power train: transfer case (4-wheel drive)
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
75,000
Reported to NHTSA
1997-11-13
Owners notified
1998-02-16

Defect description

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.

Safety risk

THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.

Manufacturer remedy

DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

Owner complaints

A complaint is one person's report to a federal agency. It is not a finding.

ComponentComplaintsMedian mileage
Electrical system: ignition: switch34
Power train: automatic transmission34
Power train: automatic transmission: lever and linkage: column shift21142,297 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip19
Air bags: frontal15
Engine and engine cooling: engine14
Equipment: appliance: air conditioner14
Service brakes, hydraulic: foundation components: hoses, lines/piping, and fittings1368,000 mi
Air bags10
Engine and engine cooling: engine: gasoline10
Power train: transfer case (4-wheel drive)10
Service brakes, hydraulic: foundation components10
Service brakes, hydraulic: foundation components: disc: rotor9
Vehicle speed control8
Electrical system: ignition7
Electrical system: wiring: front underhood7
Exterior lighting: headlights7142,000 mi
Power train: automatic transmission: park/neutral start interlock switch7
Steering: steering wheel/handle bar7
Air bags: frontal: sensor/control module6
Exterior lighting: headlights: switch6
Latches/locks/linkages: doors: latch6
Structure: body: door6
Visibility: defroster/defogger/hvac system: heater core6
Electrical system: wiring5150,000 mi
Service brakes, hydraulic: foundation components: disc: pads5
Electrical system: wiring: interior/under dash4
Exterior lighting: brake lights4
Parking brake: conventional4
Power train4
Suspension4
Tires412,000 mi
Tires: tread/belt4186,424 mi
Unknown or other4
Visibility: power window devices and controls4
Wheels4
Electrical system: alternator/generator/regulator3
Electrical system: horn3
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings3
Seat belts: front: retractor3
Service brakes, hydraulic: foundation components: disc3
Steering: hydraulic power assist system3
Visibility: windshield3
Electrical system2
Electrical system: wiring: fuses and circuit breakers2
Engine and engine cooling: exhaust system2
Equipment: mechanical: carrier/rack2
Exterior lighting: tail lights2
Fuel system, gasoline2
Power train: automatic transmission: cooling unit and lines2
Power train: manual transmission2194,000 mi
Seat belts2
Seats: front assembly: recliner2236,000 mi
Service brakes, hydraulic: foundation components: disc: caliper2
Service brakes, hydraulic: foundation components: master cylinder2
Steering: hydraulic power assist: pump2
Steering: linkages2
Structure: body: door: hinge and attachments2
Suspension: front2
Tires: temporary/emergency spare tire2120,000 mi
Vehicle speed control: accelerator pedal2
Vehicle speed control: cruise control2145,681 mi
Visibility: defroster/defogger/hvac system2
Air bags: side/window1
Electrical system: ignition: module1
Electrical system: starter assembly1
Engine and engine cooling: cooling system1
Engine and engine cooling: cooling system: hoses/lines/piping/fittings1
Engine and engine cooling: engine: gasoline: belts and associated pulleys1
Engine and engine cooling: exhaust system: manifold/header/muffler/tail pipe1
Equipment: electrical1
Equipment: electrical: radio/tape deck/CD etc.1
Exterior lighting1
Exterior lighting: back up lights1
Exterior lighting: turn signal1
Exterior lighting: turn signal: flasher unit1
Fuel system, gasoline: carburetor system1
Fuel system, gasoline: delivery1
Fuel system, gasoline: delivery: fuel pump1
Fuel system, gasoline: storage: tank assembly1
Fuel system, other: delivery: hoses, lines/piping, and fittings1
Latches/locks/linkages1
Latches/locks/linkages: hood: latch1
Parking brake: conventional: mechanical: linkage and cable1
Power train: automatic transmission: gear position indication (PRNDL)1
Power train: automatic transmission: torque converter1
Power train: axle assembly1
Power train: axle assembly: axle shaft1
Power train: clutch assembly1
Power train: driveline: constant velocity joint1
Power train: driveline: driveshaft1
Seat belts: front: anchorage1
Seat belts: front: buckle assembly1
Seat belts: front: webbing1
Seats1
Service brakes, air: antilock1
Steering: gear box (other than rack and pinion)1
Steering: linkages: knuckle: spindle: arm1
Steering: rack and pinion1
Structure1
Structure: body1
Structure: body: hatchback/liftgate: support device/strut1
Suspension: front: control arm: lower ball joint1
Suspension: rear: springs: air suspension system: springs/bags1
Wheels: lugs/nuts/bolts/studs1

The 1991 model has about 1.5 times as many complaints as this one. The 1993 model has roughly the same number of complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.