1991 Ford Aerostar recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-20. Recalls apply to specific VINs — run your VIN to confirm.
4 safety recalls, most serious first
1. Electrical system
What's wrong, in plain English: Wiring, modules, batteries. Short circuits can cause stalls or fires. THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
What could happen: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
The fix: DEALERS WILL REPLACE THE IGNITION SWITCH.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 AEROSTAR.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 96V071000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: ELECTRICAL SYSTEM:IGNITION
Summary: THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Consequence: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.
Notes: SYSTEM: ELECTRICAL; IGNITION SWITCH. VEHICLE DESCRIPTION: PASSENGER AND MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
2. Brakes
What's wrong, in plain English: Anything that slows the car down. Treat brake recalls as urgent. EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
What could happen: LOSS OF BRAKING CAN RESULT.
The fix: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 AEROSTAR.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 98E010000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: SERVICE BRAKES, AIR:DISC:ROTOR
Summary: EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
Consequence: LOSS OF BRAKING CAN RESULT.
Remedy: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
Notes: OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING APRIL 1998. OWNERS WHO DO NOT RECEIVE THE FREE ROTORS WITHIN A REASONABLE TIME SHOULD CONTACT AIMCO AT 815-759-7935. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
3. Seat belts
What's wrong, in plain English: Seat belts may not hold you in a crash. SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
What could happen: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
The fix: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 AEROSTAR.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 91V164000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: SEAT BELTS:FRONT:ANCHORAGE
Summary: SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Consequence: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
Notes: SYSTEM: SEAT BELT ANCHORAGE; FMVSS 210.VEHICLE DESCRIPTION: VANS.NOTE: THIS RECALL IS BEING CONDUCTED BY SHERROD VANS, INC.
4. Transmission / drivetrain
What's wrong, in plain English: The parts that send engine power to the wheels. Failure can mean a sudden loss of power or the car rolling away. WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
What could happen: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VE…
The fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 AEROSTAR.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 91V189000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: POWER TRAIN:AUTOMATIC TRANSMISSION
Summary: WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Consequence: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VEHICLE ACCIDENT.
Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
Notes: SYSTEM: TRANSMISSION.VEHICLE DESCRIPTION: PICKUP TRUCKS, VANS, AND MULTI-PURPOSE VEHICLES EQUIPPEDWITH A4LD AUTOMATIC TRANSMISSIONS.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- Portable jump starter
- 1991 Ford Aerostar owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Electrical system (74), Transmission / drivetrain (51), Brakes (37), Hydraulic (33), Vehicle Speed Control (23).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
06/11/2017 · Electrical system
I HAD MY STARTER REPLACED BREAKS AND RELAY AND IT STILL HAVING PROBLEMS WITH THE ELECTRICAL SYSTEM I CANNOT EVEN TURN ON MY HEADLIGHTS
02/21/2006 · Unknown Or Other
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM
05/16/2005 · Electrical system · fire
I OWNED A 1991 FORD AEROSTAR WHICH BURST INTO FLAMES AND WAS DESTROYED. I HAVE BEEN BOUNCED AROUND TRYING TO GET SATISFACTIONS BUT SINCE THERE WAS AN ONGOING CLASS ACTION LAW SUIT HAVE NOT RECEIVED ANY COMPENSATION. THE CONSUMERS WIFE NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER, RAN TO CALL THE FIRE DEPARTMENT, BUT BY THE TIME…
08/06/2004 · Brakes
THE FRONT BRAKE ROTORS WARPED, CAUSING THE VEHICLE TO SHIMMY. DEALERSHIP REPAIRED THE PROBLEM TWICE, BUT THE CONSUMER WAS STILL HAVING THE SAME PROBLEMS. *AK
05/17/2004 · Transmission / drivetrain · fire
WHILE DRIVING 65 MPH ANOTHER MOTORIST YELLED AT THE CONSUMER THAT THE VAN WAS ON FIRE. THE FIRE APPEARED TO BE COMING FORM THE MIDDLE TO THE REAR. CONSUMER PULLED OVER, AND NOTICED TRANSMISSION FLUID ON THE UNDERSIDE OF THE VAN. CONSUMER SHUT THE ENGINE OFF, AND FIRE WENT OUT. A TECHNICIAN EXAMINED THE VAN AND STATED THAT THE TRANSFER CASE NEEDED TO BE REPL…
01/15/2004 · Brakes
BRAKES OVERHEAT ON A CURVEY ROAD
01/15/2004 · Engine
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
01/15/2004 · Unknown Or Other
TRANSMISSION FLUID ENTERING COOLANT