1990 Ford Aerostar Problems

What owners report

Complaints on this model year cluster around two themes: engine-compartment and dash fires attributed to electrical wiring, the ignition switch and the alternator, and cracks in the plastic fuel tank that let fuel and fumes escape. Transmission complaints center on the van rolling while the lever is in Park, and brake complaints describe the pedal sinking to the floor or the rear ABS locking up. Many reports are on high-mileage vans, though the wiring and tank complaints appear across a wide mileage range.

1. 1
   Electrical system

   Engine-compartment and dash fires (electrical)

   • 39 complaints (20%)
   • typically at 7.8 yrs old
   • 36 mention a crash, fire or injury
   • filed 1995–2002

   Owners describe smoke or a burning smell, often while driving or shortly after parking, followed by flames from under the hood, the dash or the steering column area. Several reports say the fire started at the alternator or its wiring connection, and others point to the ignition switch; some vehicles were parked and unattended when the fire began. A number of owners mention the ignition switch recall having already been performed, and some believe the replacement part did not end the problem. No clear mileage pattern in the sample; fires are reported both while driving and hours after parking, including on vehicles that had prior ignition switch work.

   Recall 96V071000

   What to check: Ask whether the ignition switch recall 96V071000 was completed and have the alternator, its harness connector and the under-dash wiring inspected for heat damage or loose connections. Check for a burning smell or scorched insulation around the steering column.

   2 excerpts from owner complaints in NHTSA records

   “Van just died out. Then all of a sudden the van started to fill with smoke and fire and bursted into flames. Fire believed to have started in the engine. The fire was put out by the fire department. Van had over $5,000.00 dollars worth of damage. The van has been totalled. Fire department stated that fire was caused by electrical problem. Manufacturer was contacted.”

   NHTSA complaint #827569, filed 1998-08

   “Consumer noticed a smoky smell in vehicle, child had noticed white smoke coming from vent, pulled to side of road, lifted hood & noticed a lot of smoke coming from alterantor, consumer has taken vehicle to dealership. Consumer stated there were flames coming from under the hood, the vehicle was totalled.”

   NHTSA complaint #829014, filed 1998-10
2. 2
   Fuel system

   Cracked plastic fuel tank, fuel smell and leaks

   • 21 complaints (11%)
   • median 142,143 mi at 16.0 yrs old (1 states mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2005

   Complaints describe a crack developing in the upper part of the plastic fuel tank, producing a fuel smell in and around the van and, in some cases, visible leakage at the filler neck or the top of the tank. Owners report fuel odors strong enough to make passengers lightheaded, and several say the tank had to be replaced. Some owners state the tank recall was not honored for their vehicle because of the VIN or the crack location, while others received the notice but had no symptoms at the time. Reported from roughly 140,000 miles upward in the sample; several complaints tie the cracking to hot climates and long-term exposure to high temperatures.

   Recall 98V190000

   What to check: Check whether recall 98V190000 applies to the vehicle by VIN and whether it was performed, and look and smell for fuel residue or staining on the top of the tank and around the filler neck.

   2 excerpts from owner complaints in NHTSA records

   “1990 Ford Aerostar had crack in fuel tank causing consumer to replace the tank. ***no answer required*** the consumer received a recall letter in dec 1998 regarding the gas tank, however at the time he was not experiencing problems with the gas tank. The consumer is now requesting reimbursement for the gas tank that he had to replace.”

   NHTSA complaint #10142129, filed 2005-10, 142,143 miles

   “Nhtsarecall 98-v-190-000 concerning upper portion of fuel tank that can develop small cracks due to extended exposure to very high ambient temperatures. Fuel vapor or leakage could occur at these cracks. Consumer hadthe recall letter, but manufacturer didn't honor it. Please provide further information.ts.”

   NHTSA complaint #10004422, filed 2003-01
3. 3
   Brakes

   Brake pedal sinks or rear brakes lock up

   • 18 complaints (9%)
   • median 190,000 mi at 4.9 yrs old (1 states mileage, few)
   • 6 mention a crash, fire or injury
   • filed 1995–2003

   Owners describe the brake pedal traveling to the floor with little or no braking, sometimes intermittently, when backing up or at low speed. Others report the rear ABS engaging and the rear brakes locking during stops in rain or on slick surfaces, with the rear of the van stepping sideways and the ABS light coming on. Complaints also mention cracked rubber tips on a vacuum line to the brake booster causing loss of assist, and dealers reportedly could not reproduce some of the ABS symptoms. Reported on vehicles from about 12,000 to 190,000 miles; some accounts link the loss of assist to hot weather and startup.

   Recall 89V223000

   What to check: Check whether recall 89V223000 (master cylinder secondary circuit) applies and was done, inspect the master cylinder for fluid loss and the vacuum line to the booster for cracked rubber ends, and ask whether the ABS light has come on.

   2 excerpts from owner complaints in NHTSA records

   “The rear anti lock brakes have malfunctioned, causing the brakes to lock. As a result the steering lock and the vehicle lost control. No report of airbag deployment. Please provide additional information.”

   NHTSA complaint #10048473, filed 2003-11, 190,000 miles

   “Abs brakes; when applying brakes in a sudden stop the rear brakes locked up, causing rear of vehicle to pull from right to left, causing an accident, in which vehicle rolled over. Please provide details. Consumer stated that the anti-lock brake light would illuminate, consumer also stated when brakes are applied the rear end of vehicle would fishtail. Consumer took vehicle in for service, but dealer could not duplicate problem. …”

   NHTSA complaint #825549, filed 1998-07
4. 4
   Transmission and drivetrain

   Van rolls away while in Park

   • 14 complaints (7%)
   • median 115,000 mi at 13.9 yrs old (2 state mileage, few)
   • 6 mention a crash, fire or injury
   • filed 1995–2004

   Owners report the van moving after the shift lever is placed in Park, sometimes rolling downhill and striking another vehicle or object, and in one case a child moved the lever back to Park without stopping the roll. Complaints also describe harsh or delayed shifting, no overdrive engagement, and a reverse gear that works poorly. Several owners say the park mechanism recall was never applied to their van, either because of the VIN or because the work was never done. Reported across a wide mileage range, from around 60,000 to 190,000 miles; many accounts are of high-mileage vans.

   Recall 91V189000

   What to check: Ask whether recall 91V189000 (park pawl engagement) was completed, and test that the van holds firmly when the lever is in Park on a slope, with the parking brake applied as a backup.

   2 excerpts from owner complaints in NHTSA records

   “I just got my transmission fixed but the problem was I didn't know that the Ford Aerostar has been recalled... Until now I have the same problem sometimes no shifting, reverse always have a problem and late shifting (forward).. I'm just wondering if my vehicle has already been fixed? Can Ford dealer fix my van without any cost?”

   NHTSA complaint #10071345, filed 2004-01, 170,000 miles

   “Upon starting the vehicle, it accelerated at a high speed and crashed into a building. The driver's foot was on the brake pedal when sudden acceleration occurred. The vehicle was totaled. The insurance company indicated that the incident was inconclusive. There was a transmission recall 91v189000, but this vehicle was not included in the recall due to VIN.”

   NHTSA complaint #10079452, filed 2004-07, 60,000 miles
5. 5
   Vehicle speed control

   Sudden unintended acceleration

   • 12 complaints (6%)
   • median 60,000 mi at 14.6 yrs old (1 states mileage, few)
   • 10 mention a crash, fire or injury
   • filed 1995–2010

   Owners report the van accelerating on its own at low speed or when shifting from Park or into Reverse, with the driver's foot on the brake in some accounts, leading to collisions with buildings, trees or other vehicles. In a few reports the engine raced as the lever was moved and the van lurched forward. Some owners were told the vehicle was not covered by the transmission recall because of the VIN, and one insurance investigation reached no conclusion about the cause. Mostly described at low speeds during startup or gear selection; the sample does not show a consistent mileage range.

   Recall 91V189000

   What to check: Have the throttle linkage, cruise control cable and engine idle checked for binding or sticking, and confirm the shift linkage moves cleanly through each gear before a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Consumer states that she had foot on brakes than put the vehicle in reverse, the vehicle accelerated and took off at great speed. Consumer wrote in stating she does not own this vehicle and never has.”

   NHTSA complaint #803622, filed 1996-10

   “1990 Ford Aerostar. Consumer states sudden acceleration nearly 20 years ago, that caused over $1,000 in damage. Tgw the consumer stated the accident happened when the vehicle was idling.”

   NHTSA complaint #10323196, filed 2010-04

Buying note. Given the age of this model year, the wiring and fuel tank issues are the ones worth checking first: confirm which open recalls by VIN were actually completed, and have the under-hood wiring and the top of the fuel tank inspected. A pre-purchase inspection of the brakes and the park mechanism is also worthwhile on a van this old.

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.