Model year record

1994 Ford Aerostar

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

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.