Model year record

1994 Ford Aerostar

3 recall campaigns on file for this model year. 384 owner complaints on file.

Recalls

Recall campaignNHTSA 99V028000

Electrical system: wiring: front underhood

Component
Electrical system: wiring: front underhood
Manufacturer
FORD MOTOR COMPANY
Vehicles affected
23,097
Reported to NHTSA
1999-02-09
Owners notified
1999-04-07

Defect description

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.

Safety risk

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.

Manufacturer 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.

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
Air bags28120,000 mi
Electrical system: ignition: switch23
Air bags: frontal1690,000 mi
Power train: automatic transmission15
Power train: automatic transmission: lever and linkage: column shift14
Electrical system: horn12120,000 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip12
Electrical system: wiring: front underhood11100,000 mi
Vehicle speed control9120,000 mi
Steering: steering wheel/handle bar8200,000 mi
Electrical system: wiring7
Electrical system: wiring: interior/under dash7
Engine and engine cooling: engine7100,000 mi
Unknown or other7
Electrical system: ignition6110,000 mi
Fuel system, gasoline: delivery: fuel pump6
Power train: transfer case (4-wheel drive)6
Service brakes, hydraulic: foundation components6
Tires6
Electrical system593,000 mi
Engine and engine cooling: engine: gasoline5
Seat belts: front: buckle assembly5100,000 mi
Fuel system, gasoline: storage: tank assembly4
Seats4
Seats: front assembly: recliner4
Service brakes, hydraulic: foundation components: disc: rotor4
Structure: body: door4
Structure: body: hatchback/liftgate: support device/strut4
Suspension: front: shock absorber4120,000 mi
Tires: tread/belt4
Engine and engine cooling: cooling system3
Engine and engine cooling: exhaust system: emission control: catalytic convertor3
Exterior lighting: headlights3120,000 mi
Fuel system, gasoline3
Seat belts3
Service brakes, hydraulic: foundation components: disc: pads3
Steering: rack and pinion3
Structure: body: tailgate: hinge and attachments3
Visibility: defroster/defogger/hvac system: heater core3
Wheels3
Electrical system: 12V/24V/48V battery2120,000 mi
Electrical system: starter assembly2
Engine and engine cooling2
Equipment: appliance: air conditioner2
Equipment: electrical2
Exterior lighting: headlights: high/low beam dimmer switch2
Exterior lighting: tail lights2120,000 mi
Exterior lighting: turn signal: switch2
Fuel system, gasoline: fuel injection system2
Fuel system, gasoline: fuel injection system: injectors2
Power train2
Power train: clutch assembly: bell housing2120,000 mi
Power train: driveline: driveshaft2
Seat belts: front: anchorage2
Seat belts: front: retractor2
Steering2
Steering: column270,000 mi
Steering: linkages: arm: idler and attachment2
Steering: linkages: tie rod assembly2120,000 mi
Suspension2
Suspension: front2120,000 mi
Suspension: rear2
Vehicle speed control: accelerator pedal2
Visibility: power window devices and controls2
Visibility: windshield wiper/washer2
Air bags: frontal: sensor/control module1
Electrical system: alternator/generator/regulator1120,000 mi
Electrical system: ignition: module1120,000 mi
Electrical system: starter assembly: solenoid1120,000 mi
Electrical system: wiring: fuses and circuit breakers1
Engine and engine cooling: cooling system: radiator assembly1
Engine and engine cooling: engine: gasoline: belts and associated pulleys1
Engine and engine cooling: exhaust system1
Engine and engine cooling: exhaust system: emission control1
Engine and engine cooling: exhaust system: manifold/header/muffler/tail pipe1
Equipment: mechanical: accessory scissor/screw/bottle jack/lift1
Exterior lighting: brake lights1120,000 mi
Exterior lighting: tail lights: switch1
Exterior lighting: turn signal1
Fuel system, gasoline: carburetor system1
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings1
Fuel system, other1
Interior lighting1
Latches/locks/linkages: doors: latch1
Latches/locks/linkages: hatchback/liftgate: lock1
Power train: automatic transmission: cooling unit and lines1
Power train: automatic transmission: gear position indication (PRNDL)1
Power train: automatic transmission: park/neutral start interlock switch1
Power train: axle assembly1
Power train: axle assembly: axle shaft1
Power train: clutch assembly: pedal/hand lever(motorcycle)1
Power train: driveline: differential unit1
Service brakes, air: antilock: ABS warning light1
Service brakes, air: disc: pads1120,000 mi
Service brakes, air: disc: rotor1
Service brakes, hydraulic: brake fluid low warning: lamp1
Service brakes, hydraulic: foundation components: hoses, lines/piping, and fittings1
Service brakes, hydraulic: foundation components: master cylinder1
Steering: gear box (other than rack and pinion)1
Steering: hydraulic power assist system1
Steering: hydraulic power assist: hose, piping, and connections1
Structure: body1
Structure: body: door: hinge and attachments1
Structure: body: hatchback/liftgate1
Structure: frame and members1109,089 mi
Structure: frame and members: underbody shields1120,000 mi
Suspension: front: springs: coil springs1120,000 mi
Suspension: rear: springs1147,000 mi
Suspension: rear: springs: coil springs1120,000 mi
Tires: temporary/emergency spare tire1
Vehicle speed control: cruise control1125,000 mi
Visibility: rearview mirrors/devices1
Visibility: windshield1
Visibility: windshield wiper/washer: switch/wiring1105,800 mi
Wheels: lugs/nuts/bolts/studs1120,000 mi
Wheels: rim1120,000 mi

The 1993 model has about half as many complaints as this one. The 1995 model has 2 times as many 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.