1993 Ford Aerostar Problems

What owners report

Owners of this 1993 Aerostar most often describe electrical trouble, especially around the ignition switch, headlight switch and steering-column wiring, plus transmission and driveline work and recurring brake complaints. Many of these reports were filed years after purchase, and owners often describe problems at high mileage on an aging van, with a number of them about how recall repairs were handled rather than new failures.

1. 1
   Electrical system

   Ignition switch heat, shorts and key problems

   • 52 complaints (14%)
   • median 150,000 mi at 13.0 yrs old (6 state mileage, few)
   • 15 mention a crash, fire or injury
   • filed 1996–2014

   Owners describe ignition switches that overheat, melt the surrounding plug or panel trim, and cause shorts: turn signals, interior lights, horn, cruise control and dash warnings behaving erratically. Some report needing the switch replaced more than once, and others report keys that will not turn, cannot be inserted, or stay stuck and leave the van unable to shut off. Several owners link the symptoms to the ignition switch safety recall or say the recall work did not resolve them. Reported across a wide mileage range, from about 130,000 to 170,000 miles in the sample, usually on vans already many years old.

   Recall 99V029000

   What to check: Ask whether recall 99V029000 was performed and with what parts, then check the ignition and headlight switches for heat damage, melted plugs or a hot smell after running with the lights on. Confirm the key turns freely and the engine shuts off normally.

   2 excerpts from owner complaints in NHTSA records

   “After campaign 99v029000 was completed, I still had major electrical issues, including: the turn signals not working, interior light anomolies and bogus ABS brake system warnings from the dashboard lights. I replaced the ignition switch, the issues no longer happened. I took the old switch apart, it did have the issues described in NHTSA campaign id number: 99v029000. I feel the campaign was not completed correctly on my vehicle or there is a deeper issue with the ignition switch.”

   NHTSA complaint #708233, filed 1999-07

   “While driving on the highway vehicle caught on fire because of the defect described in ignition switch electrical short 99v029000 recall. Manufacturer provided conflicting information. They told consumer by phone that the VIN number was included in the recall ,and then sent a letter indicating that the VIN number wasn't included.”

   NHTSA complaint #10087331, filed 2004-08, 130,000 miles
2. 2
   Transmission and drivetrain

   Transmission and driveshaft problems

   • 83 complaints (22%)
   • median 137,335 mi at 12.0 yrs old (4 state mileage, few)
   • 7 mention a crash, fire or injury
   • filed 1995–2015

   Complaints describe transmission failure, loss of drive, vibration and driveshaft bolts separating or the shaft dropping, sometimes after earlier warranty or recall repairs. Owners also describe a park pawl that broke while the lever was in Park, letting the van roll, and shifter or shift-tube problems that left the van unable to go into gear. Several owners say the dealer inspected the vehicle but declined to replace parts or charged for repairs they felt the recall should have covered. Often reported on high-mileage vans, with one report near 243,000 miles; several complaints relate to repair attempts made years earlier.

   Recall 97V204000

   What to check: Ask whether the transfer case and driveshaft recall (97V204000) was completed and keep the paperwork; have a shop check the driveshaft, transfer case and U-joints for vibration or loose bolts, and confirm the shifter and park pawl hold the van in place.

   2 excerpts from owner complaints in NHTSA records

   “I wiil be faxing over the information regarding this 93 Ford Aerostar. No safety defect listed in the summary. The vehicle had starting problems. The transmission failed. The A/C failed. Relay starter motor failed. The heater core failed. Power steering was inoperative. Tie rods on both tires failed. Water pump failed.”

   NHTSA complaint #722457, filed 2000-05

   “Recall number 97v20400, manufacturer's number 97s83: consumer received a recall letter, and it said for him to bring the vehicle in to be inspected and for parts to be replaced, they inspected the vehicle, but refused to replace the parts.”

   NHTSA complaint #829149, filed 1998-10
3. 3
   Air bags

   Airbag clock spring failure and non-deployment

   • 36 complaints (10%)
   • median 154,500 mi at 11.8 yrs old (2 state mileage, few)
   • 21 mention a crash, fire or injury
   • filed 1995–2005

   Owners describe a flashing airbag light together with a horn and cruise control that stop working, which dealers attributed to a clock spring in the steering column. Others report airbags that did not deploy in collisions, including rollovers and a head-on impact, sometimes in the same complaint as seat belt or steering-column concerns. Reported both on older, high-mileage vans and in collisions at ordinary road speeds, with no single mileage pattern in the sample.

   What to check: Turn the key and confirm the airbag light does not stay on or flash, and check that the horn and cruise control work. Ask whether the clock spring has ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The vehicle went over a puddle of water and lost control.. Driver's side seat belt unfastened at that point. Vehicle then rolled over four times. Upon impact, air bags did not deploy. Driver was ejected through the windshield, and sustained a broken collar bone and three broken ribs. Also passenger in the front seat sustained internal head and back injuries.”

   NHTSA complaint #10042868, filed 2003-10, 120,000 miles

   “The consumer was involved in an accident in her 1993 Ford Aerostar in which the vehicle rolled four times. None of the vehicle's air bags deployed. The consumer sustained life threatening injuries including a broken bone in her back. The manufacturer was contacted but the consumer has not received a response from them.”

   NHTSA complaint #10113755, filed 2005-03
4. 4
   Body and structure

   Sliding door and liftgate that will not latch

   • 18 complaints (5%)
   • typically at 4.3 yrs old
   • 1 mention a crash, fire or injury
   • filed 1995–2001

   Complaints describe sliding doors and liftgates that come off their tracks, will not latch or open from the inside or outside, and doors that have come open while driving. Some owners report repeat repairs to the same door, and others mention that the dealer could not identify the cause. Reported on vans of mixed age and mileage, often described as recurring after previous repairs.

   What to check: Open and close the sliding door and liftgate several times from inside and outside, check the tracks for wear, and confirm each latch holds firmly when shut.

   2 excerpts from owner complaints in NHTSA records

   “The sliding door latch malfunctioned, causing the door not to latch. Door may fly open while driving, and could result in injuries. Been to dealer numerous times, but dealer could determine the problem. Please provide further information.”

   NHTSA complaint #836511, filed 1999-04

   “While driving on the highway sliding door on the passenger's side came open. The door is closed, but owner is not sure if the door will open again or not. The dealer is not aware of the problem.”

   NHTSA complaint #861035, filed 2000-04
5. 5
   Brakes

   Warped rotors, ABS light and rear brake lockup

   • 28 complaints (7%)
   • median 108,500 mi at 10.9 yrs old (1 states mileage, few)
   • filed 1995–2003

   Owners report rotors warping repeatedly, vibration and erratic braking, and an ABS warning light that stays on after the vehicle is started. Some describe rear brakes locking up first thing in the morning or randomly during the day, and others mention master cylinder, caliper and pad replacements that did not end the problem. One owner noted that replacement rotors were packaged without clear left/right labeling. Mostly reported between roughly 90,000 and 110,000 miles in the sample, though several reports omit mileage.

   What to check: Check whether the ABS light stays on, look for grooved or scored rotors, and ask about service history for rotors, calipers and the master cylinder. Test the brakes from cold and note any lockup.

   2 excerpts from owner complaints in NHTSA records

   “Cancellation of general recall tsb94b38 which had to do with ABS general recall which Ford says is now expired. My rear brakes lockup first thing in the morning, and sometimes during the day, sometimes I get a ABS light.”

   NHTSA complaint #10033247, filed 2003-08, 108,500 miles

   “Failure on the sway bar, the sway bar is wearing, causing the steering wheel to vibrate. Sway bar and stabilizer bar links both experienced wear and were replaced. Front brakes replaced due to vibration, dealer has replaced calipers twice, brake pads twice, machined rotors, replaced rotors, and repacked heel bearings, all of these repairs occurred between 17542 and 32572 miles.”

   NHTSA complaint #802327, filed 1996-09

Buying note. Inspect the ignition and headlight switches for heat or melt damage and confirm whether the ignition switch recall was completed, then have a shop check the brakes, transmission, driveshaft and door latches before buying. Service records for recalled parts are worth asking for 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.