1991 Ford Aerostar Electrical system Problems
- Complaints
- 67about this part
- Share
- 30%of 223 total for the year
- Median mileage
- —not reported
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 67 complaints about the electrical system of the 1991 Ford Aerostar, 30% of the 223 complaints for this model year. 54 a fire, according to the filers. 1 recall campaign on record is filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I owned a 1991 Ford Aerostar which burst into flames and was destroyed. I have been bounced around trying to get satisfactions but since there was an ongoing class action law suit have not received any compensation. The consumers wife noticed smoke coming from the steering column. The consumer pulled over, ran to call the fire department, but by the time he returned the vehicle was fully engulfed in flames. Updated 04/14/10.”
NHTSA complaint #10120979, filed 2005-05“This vehicle was driven for 20 minutes when a strong odor of plastic burning was smelled. This vehicle was parked when white smoke was noticed coming out from under the hood. A few seconds passed when the vehicle caught fire and was totally involved. This vehicle was totaled.”
NHTSA complaint #747438, filed 2001-06“The key does not line up correctly in the ignition when starting the vehicle. The original switch burned in august of 96 and was replaced. This took place before the recall was issued for the ignition switch. The dealer has not been notified about the problem. (96v-071).”
NHTSA complaint #821656, filed 1998-02“Vehicle caught on fire in under dash. Vehicle was totaled. Dealer could not determine the cause of the fire. The 1991 Ford Aerostar had a recall for the ignition column (96v-071). The dealer claims to have fixed it but it caught fire.”
NHTSA complaint #872847, filed 2000-10“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 1997-06Related recalls
- 96V071000Apr 25, 1996The ignition switch could experience an internal short circuit.Covers: Ford Aerostar 1988–1991, Thunderbird 1988–1993, Mercury Cougar 1988–1993 +12 more
Electrical system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 1997 | 13 | 21% |
| 1996 | 12 | 12% |
| 1995 | 37 | 24% |
| 1994 | 69 | 27% |
| 1993 | 99 | 26% |
| 1992 | 64 | 20% |
| 1991 | 67 | 30% |
| 1990 | 56 | 29% |
| 1989 | 91 | 35% |
| 1988 | 46 | 26% |
| 1987 | 36 | 32% |
| 1986 | 20 | 38% |
Other parts of the 1991 Ford Aerostar
49 complaintsBrakes
34 complaintsVehicle speed control
23 complaintsEquipment
14 complaintsEngine cooling
13 complaintsBody and structure
9 complaintsSteering
7 complaintsLatches, locks and linkages
6 complaintsVisibility (wipers, defrost, mirrors)
6 complaintsSuspension
5 complaintsFuel system
4 complaintsExterior lighting
3 complaints
← All problems reported for the 1991 Ford Aerostar
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology