1988 Ford Aerostar Problems

What owners report

Complaints on this model year cluster around the fuel tank at the top of the tank, which owners describe cracking and seeping fuel, often only when the tank is more than half to three-quarters full, and which several owners say continued after a tank replacement. A second large group describes underhood and dashboard electrical fires or melted wiring, and a third covers seat belts that will not latch or stay latched. Most reports arrive at high mileage, so condition and repair history matter more than age alone.

1. 1
   Fuel system

   Fuel tank cracks and leaks at the top of the tank

   • 48 complaints (27%)
   • median 144,000 mi at 16.0 yrs old (5 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1995–2004

   Owners describe fuel dripping or fumes entering the cabin after refueling, typically once the tank is more than half to three-quarters full, and some report raw fuel running out while filling. Several say a replacement tank developed the same crack again, and others say the dealer inspected, found no visible crack, and declined to replace the tank. Complaints also describe dealers telling owners the vehicle fell outside the regional recall scope because of its registration state or VIN. Reported across a wide mileage range, from roughly 36,000 to 187,000 miles, and often noticed right after filling the tank.

   Recall 98V190000

   What to check: Fill the tank fully and then look and smell for leaks around the top of the tank and filler neck, and ask whether the tank was ever replaced under the fuel tank recall and when.

   2 excerpts from owner complaints in NHTSA records

   “When I received my recall notice, about the possibility of cracks in the tank, I took the vehicle to bev smith Ford. They informed me there was nothing wrong with my fuel tank, and dismissed my inquiry. Since that time, I have not been able to fill my tank with more than $6.00 worth of gas, or it leaks. I have no confidence in bev smith Ford, and I'm moving to jacksonville, florida and would like to have it re-inspected. …”

   NHTSA complaint #761028, filed 2002-04

   “On august 15, 1998, my husband and I were exiting off of 575 southbound at hwy. 92 and someone came up beside me and screamed at us to get out, the van is on fire. We got out and someone has called the fire department and they came out and put the fire out. It had burned the inside of the floor where the console is, and the engine parts are all melted and one of the firemen found some type of fuel cannisters on the ground. I had just left the gas station, I had just filled the fuel tank.”

   NHTSA complaint #700786, filed 1998-11
2. 2
   Electrical system

   Underhood or dashboard electrical fire, melted wiring

   • 39 complaints (22%)
   • median 211,319 mi at 16.0 yrs old (2 state mileage, few)
   • 33 mention a crash, fire or injury
   • filed 1995–2003

   Owners describe smoke or flames from under the hood or behind the dash, sometimes within minutes to hours of parking, with melted wires, cables and connectors and in some cases a burned-out ignition switch. A few link it to wiring insulation that had shrunk and shorted, and one describes the ignition switch shorting out. Often reported after the vehicle sat parked, at mileages spanning roughly 36,000 to 386,000.

   Recall 96V071000Recall 88V091000

   What to check: Ask whether the ignition switch was replaced under the ignition switch recall, and have a shop look over the engine bay and dash wiring, especially any brittle or repaired harness sections, before buying.

   2 excerpts from owner complaints in NHTSA records

   “Truck experienced electrical system failure. As a result the truck caught on fire within two hours after being parked. The fire originated under the hood. All the under hood electrical components were melted. The heat also cracked the windshield.”

   NHTSA complaint #10046164, filed 2003-11, 36,520 miles

   “Vehicle caught on fire 6 hours after being parked. State fire marshall determined that ignition switch caused fire. Home and vehicle were totaly lost. 3 children had to jump through window to escape the fire, one sliced tendons on wrist. Ignition switch was replaced under recall 96v071000 on 30 sep 1997. Information provided by sherrie hansen, attorney.”

   NHTSA complaint #896761, filed 2001-09
3. 3
   Seat belts

   Real seat belts that will not latch or hold

   • 16 complaints (9%)
   • typically at 8.4 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2000

   Owners describe the driver's buckle failing to latch, a broken spring inside the buckle, or a belt that releases with slight tension, and some note slack that had to be adjusted while driving. One report describes front belts that did not lock up in a collision, and another notes the rear outboard positions have lap belts only. Filed mostly on vehicles without mileage recorded; the condition appears with age and use rather than at a specific mileage.

   What to check: Pull each belt out fully and latch and unlatch it several times, checking that the buckle clicks positively and the belt locks when tugged sharply.

   2 excerpts from owner complaints in NHTSA records

   “This vehicle is not equipped with shoulder belts in the rear seats. I have a three-year-old son that is quickly outgrowing his safety seat. (a century model that fits in the middle of the 2nd seat position and is restrained by a lap belt). I have purchased a high back booster seat (again a century) that like all of the high backed booster seats I have seen, require the use of a lap and shoulder belt. I have tried to obtain information about installing aftermarket shoulder straps from Ford motor company. …”

   NHTSA complaint #710724, filed 1999-08

   “Driver's seat belt will not latch, spring broken in female part, if you do manage to get it hooked it will release with the slightest tension. Prior to this seatbelt also had slack would have to adjust it while driving.”

   NHTSA complaint #705614, filed 1999-04

Buying note. These vans are old enough that condition and repair records outweigh the model year itself; the fuel tank and the wiring are the two areas worth inspecting personally, and confirming recall work was actually completed is worth the effort. If belts or wiring look original, budget for replacing them rather than relying on the seller's assurances.

Summary written with AI from a sample of 60 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.