1989 Ford Aerostar Problems

What owners report

Owners of the 1989 Ford Aerostar most often describe electrical problems, especially ignition switch faults that led to stalling, a key that could be removed in any gear, and in several reports smoke or fire at the steering column or under the hood. The second large theme is fuel leaking from the top of the gas tank, which many owners tie to recall 98V190000 and describe as recurring even after repair. Reported mileages are high, so most of these complaints reflect older, well-used vans rather than low-mileage failures.

1. 1
   Electrical system

   Ignition switch overheating, smoke and fire

   • 84 complaints (32%)
   • median 181,500 mi at 17.5 yrs old (2 state mileage, few)
   • 65 mention a crash, fire or injury
   • filed 1995–2006

   Owners describe the ignition switch or steering column becoming hot while driving, smoke coming from the column or dash, and a burning-wiring smell. Several reports describe the van catching fire while parked or shortly after being shut off, sometimes in the front engine area, and one owner found the key could be removed in any gear or the ignition stuck on until the battery cable was disconnected. Some mention replacing the ignition switch or ignition module, and complaints describe repeated stalling that was not resolved by repairs. Described in vans of widely varying age and mileage, from parked-in-garage fires to late-life stalling; the sample includes one report near 208,000 miles.

   Recall 96V071000

   What to check: Ask whether the ignition switch was replaced under recall 96V071000 and whether any wiring or column repairs were done. Check for a hot or loose ignition switch, a key that comes out in gear, and any burnt smell or scorching around the column.

   2 excerpts from owner complaints in NHTSA records

   “My Ford Aerostar caught fire last night for no apparent reason. My daughter had returned from school and parked it in the driveway. Approximately 2 hours later, a neighbor rang the door bell and frantically said your van is on fire . We called 911 and the fire department was there within 3 minutes to put it out.”

   NHTSA complaint #10169816, filed 2006-10, 155,000 miles

   “The vehicle was driven home from work (aprox 10 min drive) and parked for about 10 minutes when my son noticed the van was on fire, flames were coming out the front thru the radiator opening, by the time the fire dept arrived, the entire front of the van was engulfed in flames. The front of the van is now unrecognizable and a total loss. In additon, we lost several hundred dollars in personal effects.”

   NHTSA complaint #719862, filed 2000-03
2. 2
   Fuel system

   Fuel leaking from top of gas tank

   • 48 complaints (18%)
   • median 167,500 mi at 15.1 yrs old (2 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1995–2004

   Owners report a strong gasoline smell and fuel leaking from the top of the tank, typically noticed after filling up and easing as the level drops. Several say the tank was found cracked and replaced, and some report the replacement tank leaked the same way. Complaints describe dealers cleaning only the grommet, declining the repair because the vehicle was not covered by the recall, or saying no parts were available. Mostly reported on older vans; several complaints occurred around or after the 1998 recall campaign, and the sample's higher-mileage reports are near 160,000 to 175,000 miles.

   Recall 98V190000

   What to check: Fill the tank fully and look and smell for leaks at the top of the tank; ask whether recall 98V190000 was performed and whether the tank has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I just had my fuel tank replaced because of cracks in top of fuel tank per a recall notice I received from Ford (98m03 kit bb). However, they replaced the previous metal tank with a plastic fuel tank. I have never heard of plastic fuel tanks being allowed on vehicles. I do not believe a plastic tank can be as safe as a metal tank. Is it legal to put a plastic fuel tank on a car/truck??”

   NHTSA complaint #701475, filed 1998-12

   “The gas tank was leaking fumes, then we noticed a puddle of gas under the vehicle after filling the tank. We contacted Ford after reading about the recall # 98mo3 regarding the same problem we were having. Initially they were going to let the dealer decide if we fell under the recall then decided that since we were registered in nj not in one of the states they listed that we were not eligible for the recall. Has anyone else reported the same problem outside of the states Ford lists? If so possibly their recall should have a wider area. …”

   NHTSA complaint #725642, filed 2000-07
3. 3
   Seat belts

   Seat belt buckle will not latch or release

   • 20 complaints (8%)
   • typically at 8.0 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–1999

   Owners describe buckles that will not click or latch, and in some cases a buckle that locks and will not release. Several mention a broken spring inside the buckle and being told the whole belt assembly had to be replaced, with parts scarce. One complaint asks about adding shoulder belts for a child in the rear lap-belt positions. Frequently reported on vans that were already several years old; the sample does not give reliable mileage for most of these complaints.

   Recall 91V164000

   What to check: Buckle and unbuckle every belt, front and rear, and check that each clicks and releases cleanly; ask whether any belt assemblies were replaced.

   2 excerpts from owner complaints in NHTSA records

   “The consumer has been experiencing problems with passenger and driver seat belts. Passenger's seat belt locked up and would not unfasten. The consumer had to cut child out of the seat belt. In addition, the driver's side seat belt won't fasten. The manufacturer has yet to be contacted.”

   NHTSA complaint #832266, filed 1998-12

   “The drivers side seatbelt buckle broke and no longer latched. Please describe. Tt repair garage stated that only one new part could be found in all the us and that Ford did have any in stock, and would not make any new ones for 3-4 weeks.”

   NHTSA complaint #975032, filed 1995-11
4. 4
   Transmission and drivetrain

   Van rolls or moves out of park

   • 19 complaints (7%)
   • typically at 8.0 yrs old
   • 10 mention a crash, fire or injury
   • filed 1995–2000

   Owners report the van moving or rolling after being placed in park, including on an incline, and in some cases the shifter could be moved out of park without the key in the ignition. Reports describe the vehicle rolling into a fence and down an embankment. Reports come from vans of various ages; the sample gives no reliable mileage for these complaints.

   Recall 91V189000

   What to check: On level ground and with the brake held, check that park holds firmly and that the shifter cannot be moved without the key; ask whether the park pawl or shift linkage was serviced under recall 91V189000.

   An excerpt from owner complaints in NHTSA records

   “My two year old son got into the vehicle and slipped the shifter out of the park position without the keys, and the vehicle had been parked for over 24 hours, the van rolled backwards through my fence, down an embankment and smashed into a tree stump, with my son inside. The van was totaled and my son was brought to the hospital with a cervical sprain.”

   NHTSA complaint #706214, filed 1999-05
5. 5
   Vehicle speed control

   Sudden acceleration or surging at low speed

   • 11 complaints (4%)
   • median 102,371 mi at 9.8 yrs old (1 states mileage, few)
   • 8 mention a crash, fire or injury
   • filed 1995–2004

   Owners describe the van surging or taking off unexpectedly when shifting into gear, while parking, or while braking, in a few cases striking a building or another vehicle. Some reports say the dealer suspected an idle air control fault or an electrical chip problem, and one owner reported the problem returned after repair. Reported mostly on vans past 100,000 miles in the sample, often during parking or low-speed maneuvering.

   What to check: During a test drive, check for idle surging and any lurch when shifting from park into gear, and ask about prior idle air control or throttle repairs.

   2 excerpts from owner complaints in NHTSA records

   “The consumer stated that back in 1998 she had a accident with her Ford Aerostar. She stated that when she pulled into a parking space and hit the brakes, the vehicle surged forward and hit a building. She said she had the vehicle towed to the dealer who stated that they thought the problem was a faulty idle air control. She said it was repaired and she took the part and sent it to the manufacturer. Now the problem has come up again and she was asked to be a witness, because someone was killed, when their vehicle did the same thing. …”

   NHTSA complaint #10097085, filed 2004-11, 102,371 miles

   “While starting vehicle and putting it into gear, vehicle suddenly took off, causing owner to strike another vehicle. Vehicle also surged. Dealers stated possible electric chip failure.”

   NHTSA complaint #818875, filed 1997-12

Buying note. On this model year, inspect the fuel tank for leaks after a full fill-up, test every seat belt buckle, and confirm that park holds and that any ignition switch recall work was done. With typical reports coming at high mileage, a pre-purchase inspection focused on wiring and the fuel system is worth the cost.

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.