1991 Ford Aerostar Problems

What owners report

Complaints about this model year cluster around electrical fires and wiring problems, the automatic transmission and transfer case, and brakes. Many reports describe smoke or fire from the steering column or under the dash, and several transmission complaints involve the vehicle moving out of park or a transfer case giving out at highway speed. Reported mileages vary widely, from well-used vans to low reported odometer figures in the sample.

1. 1
   Electrical system

   Under-dash and steering column fires

   • 54 complaints (24%)
   • typically at 5.9 yrs old
   • 48 mention a crash, fire or injury
   • filed 1995–2005

   Owners describe smoke or flames coming from the steering column, ignition switch, or under the dash, sometimes while parked and sometimes while driving. Several say the vehicle was totaled, and some note the ignition switch had already been replaced under a recall before the fire occurred. Complaints mention dealers being unable to duplicate or determine the cause, and in some cases declining responsibility for the repair parts. Reported from the mid-1990s through the early 2000s, with no clear mileage pattern in the sample; several occurred while parked or shortly after driving.

   Recall 96V071000

   What to check: Ask whether the ignition switch recall 96V071000 was completed, and inspect the steering column and under-dash wiring for signs of heat damage, melted plastic, or previous repairs.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle was in the park position for 15 to 20 min when the vehicle caught on fire in the wiring harness and the ignition switch. Consumer stated the recall was corrected. Fire department determined the fire as an electrical fire. Consumer turned the vehicle off removed the key which meant the gear shifter should have been locked in park. The consumer son moved the gear shift out of park and it rolled into other vehicle.”

   NHTSA complaint #813073, filed 1997-06

   “While parked a short in the alternator caused the vehicle to catch on fire. Consumer states the vehicle would not sparking/catching fire until the battery was disconnected, consumer received recall 96v071 regarding a possible short circuit that could develop in the ignition switch, however when consumer mentioned this to dealerhip, they stated that this was not the reason for the short and would not reimburse consumer for damages.”

   NHTSA complaint #804566, filed 1996-11
2. 2
   Transmission and drivetrain

   Transfer case and driveline vibration

   • 13 complaints (6%)
   • typically at 8.0 yrs old
   • 2 mention a crash, fire or injury
   • filed 1996–2004

   Owners describe a vibration that grows with speed, often at highway speeds, followed by fluid leaks, smoke from underneath, and loss of transmission function. Several complaints attribute this to the transfer case or driveshaft, with mechanics reporting a destroyed transfer case that needed replacement. Some owners say they later learned of a transfer case or driveshaft recall that did not cover their van. Mostly reported above highway speeds; filed from the mid-1990s through 2004, with several mentions of vans over 70,000 miles.

   What to check: Drive the van at highway speed and feel for vibration through the floor and steering, then inspect the underside for fluid leaks or residue around the transfer case and exhaust.

   2 excerpts from owner complaints in NHTSA records

   “Consumer was traveling about 75mph on highway when driveshaft bent, causing the failure of the transfer case and transmission. Vehicle was vibrating and there was transmission fluid leaking from underneath vehicle. There were no prior warning. He took vehicle to dealership, and mechanic told him that his vehicle wasn't on recall.”

   NHTSA complaint #868915, filed 2000-08

   “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 replaced. Nhtsa recall campaign 99v094000 was issued.”

   NHTSA complaint #10073700, filed 2004-05
3. 3
   Transmission and drivetrain

   Van rolls or shifts out of park

   • 41 complaints (18%)
   • typically at 5.5 yrs old
   • 23 mention a crash, fire or injury
   • filed 1995–2002

   Complaints describe the shifter being movable out of Park with the key removed or the ignition in lock, and vans rolling into other vehicles or structures as a result. Some owners report the key can also be removed while the transmission is in gear. Dealer responses varied, with some owners told the behavior was normal for the design and others having repairs done under recall 91V189000 without the problem going away. Reported across the late 1990s; circumstances are typically parked, engine off, sometimes with children near the shifter.

   Recall 91V189000

   What to check: With the van parked and the key removed, try moving the shifter out of Park and confirm the park pawl holds; ask whether recall 91V189000 was performed.

   2 excerpts from owner complaints in NHTSA records

   “Consumer parked vehicle in the garage, got out and took the key out of the ignition. Accidently, left the gear in reverse. Consumer then leaned against the vehicle and it began rolling backwards. The vehicle hit the side of the carport and stopped. Consumer contacted the dealer and was told that's how the vehicle was designed.”

   NHTSA complaint #814621, filed 1997-07

   “The consumer is still having problems with transmission, even after recall repairs were done. Consumer states that when the ignition is in the lock position the shifter can be taken out of park, 5 year old child moved gear shift and vehicle rolled into another vehicle causing minor damage.”

   NHTSA complaint #805287, filed 1996-11
4. 4
   Vehicle speed control

   Sudden acceleration and cruise control not releasing

   • 20 complaints (9%)
   • typically at 7.5 yrs old
   • 13 mention a crash, fire or injury
   • filed 1995–2002

   Owners report the accelerator going to the floor and sticking, sometimes right after shifting into gear, with the van accelerating into a wall or another vehicle. Others describe the cruise control failing to disengage when the brake or off button was used. Several say the dealer could not find the cause after the vehicle was towed in. Reported from the mid-1990s through the early 2000s, at a range of speeds including cruising at highway speed.

   What to check: Check that the throttle linkage and cable move freely and return fully, and test the cruise control's brake-pedal and off-switch release at low speed on a safe road.

   2 excerpts from owner complaints in NHTSA records

   “Cruise control was set on 70 MPH when unexpectedly a vehicle jumped in front of consumer who than went to apply brakes, but cruise control did not disengage. Tried pushng off button, still did not disengage ,causing the consumer to pull to the side onto median where tire was punctured. As a result, vehicle rolled over. Dealer cannot determine why cruise control did not deactivate.”

   NHTSA complaint #822607, filed 1998-04

   “Got in vehicle, put vehicle in drive, accelerator went to floor & stuck, vehicle took off, steering went back/forth, grabbed steering wheel to keep straight, stood on brakes (ABS), hit wall & a vehicle, went airborne, ended up on median w/8 lane traffic.”

   NHTSA complaint #807896, filed 1997-01
5. 5
   Brakes

   Brake pedal to the floor and fluid loss

   • 24 complaints (11%)
   • median 150,000 mi at 13.3 yrs old (1 states mileage, few)
   • 5 mention a crash, fire or injury
   • filed 1995–2004

   Owners describe the brake pedal going to the floor with little or no warning, in some cases with no fluid left in the reservoir, and a few report a brake hose found hanging free from its body bracket. Others mention a failed master cylinder and the part being on back order. Front rotor warping that produced a shimmy, recurring after repeat dealer repairs, is also reported. Reported from the mid-1990s through 2004, including one complaint at about 150,000 miles.

   What to check: Check brake fluid level and look for dampness or cracking at the flexible hoses near the front wheels and along the body brackets before and after a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Left front brake was seizing and pulling vehicle to left, after stop and go driving. I had this same experience with a 1982 Ford f-100 pickup and finally corrected it by replacing pneumonic rubber disc brake pistons with steel ones (ceramic were available, too). I feel these rubber pistons, if used, should be recalled and replaced at mfr.'s expense. This problem caused a lot of stress in a long trip in the f-150.”

   NHTSA complaint #705888, filed 1999-04

   “The front brake rotors warped, causing the vehicle to shimmy. Dealership repaired the problem twice, but the consumer was still having the same problems.”

   NHTSA complaint #10087370, filed 2004-08, 150,000 miles

Buying note. On a van this old, the most useful steps are confirming which safety recalls were actually completed and having the wiring, brake hoses, and transfer case inspected by a mechanic familiar with these vans. Service records showing regular transmission and brake maintenance matter more than the odometer reading here.

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.