Model year record

1992 Ford Aerostar

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

Ford Aerostar, 1986–1997 generation
Pictured: the 1986–1997 generation. order_242, CC BY-SA 2.0 · Wikimedia Commons

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.

Other Ford Aerostar model years

All Ford Aerostar recalls by year

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.