1992 Ford Aerostar Problems

What owners report

Owners of this 1992 Ford Aerostar report a wide range of wear- and age-related problems, most often involving the transmission and transfer case, dashboard electrical shorts, and brake hydraulic faults. Most complaints on file come from vehicles well past 100,000 miles, though brake and headlight-switch reports appear at lower mileage. Several complaints mention recalls for the all-wheel-drive transfer case and the ignition switch, with some owners saying their vehicle was not covered.

1. 1
   Transmission and drivetrain

   Transfer case / driveshaft vibration and failure (AWD)

   • 36 complaints (11%)
   • typically at 6.8 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2001

   Owners of all-wheel-drive vans describe heavy vibration and loud thumping at highway speed, followed by fluid loss and a broken transfer case. Some report the transmission, driveshaft or exhaust dropping and, in one case, the gas tank being punctured. Complaints also describe continued vibration after the recall repair was performed, and others say they were told their vehicle was outside the recall by build date or VIN. Typically reported past 100,000 miles, often at highway speeds.

   Recall 99V094000Recall 97V204000

   What to check: For an all-wheel-drive van, ask whether the transfer case recall work was completed, check for vibration or thumping on a highway test drive, and look for fluid weeping at the transfer case and transmission.

   2 excerpts from owner complaints in NHTSA records

   “This part has a safety recall (NHTSA# 97v204 or Ford recall # 97s83). However, it only includes vehicles manufactured after 1/3/92. Since my vehicle was manufactured in october, 1991 (3 months earlier) it was not covered by the recall. I have already paid for the repair of leaking fluid, but I believe I should be reimbursed and the total fix should be installed at Ford's expense to prevent additional failures and/or cause fires.”

   NHTSA complaint #702396, filed 1999-01

   “Nhtsa recall 97v20400 (Ford recall 97s83); Ford claims my vehicle not covered but won't say why. The information in recall seems to fit my situation. I am suspicious but can't get anything but the run around.”

   NHTSA complaint #704032, filed 1999-03
2. 2
   Electrical system

   Dashboard wiring shorts and ignition switch problems

   • 85 complaints (27%)
   • median 147,840 mi at 14.6 yrs old (2 state mileage, few)
   • 31 mention a crash, fire or injury
   • filed 1995–2008

   Owners describe smoke from under the dash, melted wiring and burned connectors, sometimes after the ignition is turned on or while driving. Several say the ignition switch shorted and damaged the harness, and some report fire damage or burns. Complaints also mention that wiring harness parts are no longer available and that their vehicle was not included in the ignition switch recall. Reported across a wide mileage range, including vehicles well over 100,000 miles.

   Recall 99V029000

   What to check: Ask whether the ignition switch recall was completed, and inspect under the dash for scorched or repaired wiring and a burning smell.

   2 excerpts from owner complaints in NHTSA records

   “Repaced headlight switch twice because of lights going out at night while driving. Original switch appeared as if it had gotten hot. After jumper on the wiring harness was installed after receiving recall notice in early 1999, lights have been doing great until this evening, went out like previous times. A couple of days ago the door ajar light on dash was clicking on and off.”

   NHTSA complaint #716024, filed 1999-12

   “When turning the ignition on there is a noise and vehicle starts to smoke; took to dealer, consumer doesn't want to pay for them to check the vehicle, thinks Ford should pay for it. There is information on the internet said Ford missed a lot of cars in the ignition recall .”

   NHTSA complaint #807522, filed 1997-01
3. 3
   Brakes

   Brake hose leaks and pedal going to the floor

   • 33 complaints (10%)
   • median 109,000 mi at 13.3 yrs old (2 state mileage, few)
   • 9 mention a crash, fire or injury
   • filed 1995–2007

   Owners describe the brake pedal dropping to the floor and loss of braking after a flexible brake hose split or popped off, in one case at roughly 45 mph. Others report brake line hoses cracking and leaking, and some note that the system lacks a backup circuit when a line fails. Additional complaints mention rapid pad and rotor wear and warping. Appears from around 35,000 to 145,000 miles, including in normal driving and parking-lot conditions.

   What to check: Have the flexible brake hoses and hard lines inspected for cracking, bulging or rust, and check the brake fluid level and pedal feel on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Owner was going at approximately 45 MPH. Owner applied the brakes and the brakes went to the floor. Owner says that the front right brake hose line popped right off. Causing the vehicle to lose all brake pressure preventing the vehicle from stopping. Provide further details.”

   NHTSA complaint #10108595, filed 2005-01, 68,000 miles

   “Leaks in engine, transfer case, and automatic transmission caused drivetrain to vibrate. Additionally, vehicle's brakes are dangerously inadequate. Both front discs and drums are undersized for vehicle, resulting in long stopping distances and excessive disc warping and wearing. The rear anti lock brakes are totally nonfunctional.”

   NHTSA complaint #537457, filed 1998-06
4. 4
   Air bags

   Airbag warning light and no deployment in a crash

   • 30 complaints (9%)
   • typically at 5.4 yrs old
   • 15 mention a crash, fire or injury
   • filed 1995–2001

   Owners report the airbag warning light staying on, sometimes returning after the sensor or control module was replaced. Complaints also describe bags that did not deploy in a collision, or deployed late and partially, and one case where a wiring fault was found. Dealer responses described in the complaints varied, with some owners saying the problem returned after repair. Reported from the mid-1990s onward on vehicles of various mileages.

   What to check: Check that the airbag warning light goes out after start-up and ask for any history of sensor or clock-spring replacement.

   2 excerpts from owner complaints in NHTSA records

   “During a crash bumper/hood/fender/switch/grill/core support/air conditioner condensor/fan belt/transmission and driver's door were damanged from impact to the driver's side. Also seat came off track and mechanic repaired it, as well as the air bag did not deploy.”

   NHTSA complaint #836178, filed 1999-03

   “Ie97027, while driving airbag light stays on which indicates there may be a problem with the airbag system which won't protect the occupant in event of an accident. Cause unknown. Manufacturer has not been contacted. Please provide further information.”

   NHTSA complaint #836200, filed 1999-03
5. 5
   Exterior lighting

   Headlights flickering or going out

   • 14 complaints (4%)
   • median 146,000 mi at 12.3 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2007

   Owners report headlights flickering off and back on, or failing completely, often at night and at highway speed. Complaints attribute this to the headlight switch and its connector, which in some cases showed heat damage, and several switches were replaced more than once. Some owners note the switch is heavily used in vehicles driven with lights on. Commonly reported between roughly 90,000 and 170,000 miles, often after repeated switch replacement.

   Recall 99V029000

   What to check: Test the headlights on a night drive and ask whether the headlight switch or the recall jumper has been replaced; look at the switch connector for discoloration.

   2 excerpts from owner complaints in NHTSA records

   “First started out a couple of months ago. Headlights would flicker off and then back on. I figured it was nothing. Now the headlights flicker every 30-60 seconds, can not drive vehicle at night, have already been pulled over by police because of it. I explained to the officer there must be a problem with the headlights.”

   NHTSA complaint #10010714, filed 2003-03, 142,000 miles

   “While driving at highway speeds at night, headlight switch (f49z-11654-a), with autolamp option, failed and headlights started flashing off and on then going out completely. This has occurred three times, 9/98 at 93,000 miles (switch replaced), 8/01 at 145,000 miles (new switch and block installed w/old wiring) and 10/02 at 160,000 miles (new switch and block w/new wiring installed). Vehicle normally driven with headlights on for safety so useage time on switch is extensive. …”

   NHTSA complaint #769664, filed 2002-11

Buying note. This is an old design, so condition and maintenance history matter more than the complaint list: inspect the brakes, wiring under the dash and, on all-wheel-drive vans, the transfer case carefully. Ask for documentation that any open safety recalls were completed.

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.