1987 Ford Aerostar Problems

What owners report

Complaints on this model year cluster around two themes: engine-compartment and steering-column fires traced by owners to wiring, the ignition switch, or the alternator circuit, and seat belt hardware that owners say failed to latch or lock. Fuel leaks around the tank and filler area, stalling, and transmission or throttle-control problems also appear repeatedly. Reports span many years of service and, where mileage is given, describe vans that were already well used when the problem appeared.

1. 1
   Electrical system

   Engine-compartment and steering-column fires

   • 33 complaints (29%)
   • typically at 9.7 yrs old
   • 32 mention a crash, fire or injury
   • filed 1995–2001

   Owners describe smoke or a burning smell, then flames under the hood or at the steering column, sometimes with the van parked and the engine off. Several say the wiring to the alternator, the ignition switch, or the main harness burned, and that the fire department or an insurance inspector attributed the fire to the electrical system. In many cases the van was totaled; some owners say a dealer or the manufacturer was unwilling to help. Reported across a wide range of ages and use, often with no warning beforehand and sometimes while parked.

   Recall 88V091000

   What to check: Have a mechanic inspect the alternator wiring, ignition switch, and under-hood harness for chafing, repairs, or heat damage, and ask whether any wiring recall work was done. Check for a fire extinguisher and confirm the van's insurance and history record.

   2 excerpts from owner complaints in NHTSA records

   “Parked vehicle funny odor and vehicle caught on fire underneath the hood. Consumer had driven vehicle approximately 1 mile and smelled an odor, she thought her brakes were hot, consumer then pulled to the curb, while consumer was calling for a tow truck the vehicle caught fire, consumer contacted manufacturer but they were unwilling to help.”

   NHTSA complaint #986258, filed 1996-06

   “Had service done on vehicle & replaced the old battery. Was driving when smoke started under the hood. Pulled over & parked. Lifted hood & noticed fire under the hood. Fire department called & put flames out. Had indicated it was electrical wiring for the alternator. The insurance inspector checked vehicle out & indicated wires to alternator burned & totaled out vehicle.”

   NHTSA complaint #843448, filed 1999-07
2. 2
   Vehicle speed control

   Sudden acceleration or a sticking throttle

   • 6 complaints (5%)
   • typically at 11.1 yrs old
   • filed 1995–2000

   Owners say the throttle sticks or the van surges forward or backward on its own, with or without cruise control engaged, and that the accelerator pedal squeaks and binds. Some report collisions after the van accelerated unexpectedly, and one says a dealer could not reproduce or correct the surge. Described as intermittent, occurring at start-up, at low speed, and in reverse.

   What to check: With the engine off, press the accelerator and check that the linkage and cable move freely and return fully; during a test drive, note any hanging idle or surge and have the throttle and cruise-control linkage inspected.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle experiencing problem with surges forward when starting. Intermittently, problem has occurred on several occasions. Dealer was notified and unable to locate/correct the problem. Please feel free to provide any further details.”

   NHTSA complaint #871606, filed 2000-09

   “Accelerator makes squeaking sound & would stick . Also, had to have seat belts replaced due to a malfunction. In addition, the emission light keeps coming on/the computer chip shorted out.”

   NHTSA complaint #831600, filed 1998-12
3. 3
   Seat belts

   Seat belts that do not latch or lock

   • 18 complaints (16%)
   • typically at 8.8 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2002

   Complaints describe buckles that release or fail to latch, retractors that do not lock during a collision, and insufficient tension on the rear bench center belt. Owners say occupants moved forward into the windshield or steering wheel in a crash, and that dealers either could not address the problem or declined to inspect the van. Some also mention worn webbing near the seat hinge. Reported on vans of varying age, usually noticed in use or during a collision rather than at a specific mileage.

   Recall 89V226000

   What to check: Pull each belt out fully and check that it retracts and locks when tugged sharply, inspect the webbing near the seat hinge for fraying, and ask whether the seat belt anchorage recall was completed.

   An excerpt from owner complaints in NHTSA records

   “Driving at approx 28-29mph ,when another vehicle came out unexpectedly, hitting vehicle, seatbelt which are on reels and suppose to lock on impact , did not, causing passenger to hit windshield , driver hit steering wheel due to defect , dealer has been notified, cannot do anything about problem ,refuses to look at vehicle.”

   NHTSA complaint #822060, filed 1998-03
4. 4
   Fuel system

   Fuel leaks at the tank and filler neck

   • 5 complaints (4%)
   • typically at 10.4 yrs old
   • 1 mention a crash, fire or injury
   • filed 1997–1999

   Owners report gasoline running down the tank and onto the ground, and strong fuel fumes, especially when filling the tank past about 15 gallons. Some describe repeated replacement of the filler neck grommet and seals, with the leak returning, and one says the tank itself was never inspected. A few complaints tie the leak to the spring-lock fuel line coupling at the engine. Described as recurring over years of ownership, most noticeable during or right after refueling.

   Recall 87V139000

   What to check: Fill the tank fully and look and smell for leaks around the filler neck, tank seams, and fuel lines, and ask whether the fuel line coupling recall was performed.

   2 excerpts from owner complaints in NHTSA records

   “The consumer had been experiencing problems with fuel line. While driving vehicle would leak fuel drastically. The defects described corrolate with recall number 87v139000. The manufacturer had yet to be contacted.”

   NHTSA complaint #832288, filed 1998-12

   “Whenever filling up the fuel tank would notice fuel leaking out of the gas tank, and strong gas fumes. Took vehicle to automative shop & had 2 seals replaced. The fuel tank was not inspected. Problem still exists.”

   NHTSA complaint #834042, filed 1999-01
5. 5
   Engine cooling

   Stalling, loss of power, and no restart

   • 12 complaints (11%)
   • typically at 10.6 yrs old
   • 4 mention a crash, fire or injury
   • filed 1996–2001

   Owners describe the engine quitting without warning while driving or when shifting into reverse or pulling away from a stop, sometimes followed by smoke and difficulty restarting. Several mention repeated replacement of the control module or the TFI module, and say dealers denied a pattern or could not locate the cause. Reported at varied mileages; several owners describe the stall happening repeatedly over an extended period.

   What to check: Ask for service records on ignition module, TFI module, and engine control module replacements, and test drive from cold through several stops to see whether the idle or restart is uneven.

   2 excerpts from owner complaints in NHTSA records

   “While driving between 20 MPH and 40 MPH transmission went out twice, and consumer had to have tranmission replaced. Currently, while driving at 20 MPH tranmission slips into neutral,and the consumer can't move vehicle or start the vehicle up for a while. Also, vehicle is stalling and the consumer is losing power.”

   NHTSA complaint #836100, filed 1999-03

   “We have had the control module replaced a minimum of 5 time (receipts on hand), each time the van stalls out while driving. This has caused many near crashes and much fustration only the alertness that the van stalls prevented any bodily harm. Several Ford dealerships deny any problem with the control module on this van and no recalls for this problem. The part has been replaced by the dealer.”

   NHTSA complaint #732476, filed 2000-09

Buying note. These are old vans, so condition and repair history matter more than the model year itself. Ask for records of any wiring, fuel-line, or seat belt recall work, and have a mechanic look closely at the under-hood wiring, fuel filler area, and belt hardware before purchase.

Summary written with AI from a sample of 44 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.