1994 Ford Aerostar Electrical system Problems
- Complaints
- 69about this part
- Share
- 27%of 257 total for the year
- Median mileage
- 115,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 69 complaints about the electrical system of the 1994 Ford Aerostar, 27% of the 257 complaints for this model year. Where a mileage was given, the median is 115,000 miles. 19 a fire, according to the filers. 2 recall campaigns on record are filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Front coil springs snapped, had to replaced with reading spring works, they had to send the specks to chicago. My Ford aero star 4 wheel drive & 4.0 v6 is not available from after market. The only option is to buy new or used Ford springs which are made in china. The local Ford dealer admits replacing coil & leaf springs on several models. Midas was so busy replacing Ford springs, they could not set up an appointment to install springs even if I had the springs.”
NHTSA complaint #10217895, filed 2008-02, 120,000 miles“Van had been driven for approximately two hours or so, around the local city communities. Van had been parked for approximately five minutes, when neighbors notified me of fire. Intense fire was coming from driver's side/windshield/ignition/front seat area, eventually consuming entire interior of van. Norfolk fire department responded within five minutes, or so, station only about 150 yards from my residence. Fire was extinguished within five minutes or so, but the van was completely consumed by fire and totally destroyed by then. Van was junked/salvaged. …”
NHTSA complaint #10534938, filed 2013-08, 93,000 miles“Car was parked in driveway, untouched, for at least 24 hours. Fire erupted about 7:00 am. Flames were coming through the drivers side windshield. Seemed to be electrical in nature. Car is a total loss. Car is completely original (no electric alterations). Car had been to the dealer within the last 2 years so any recall work should have been done.”
NHTSA complaint #10217101, filed 2008-02, 110,000 miles“Dt: contact stated that the air bag light on the dashboard flashed on and off. The cruise control and the horn will not work. The problem started without warning. He was told by the dealer the air bag will not work as long as the light on the dashboard was on. Also, the dealer told him he had a broken wire in the steering wheel. He has not had it repaired yet. The air bag problem was not covered under warranty or recall. Therefore, e the manufacturer will offer no free remedy.”
NHTSA complaint #10140413, filed 2005-10, 125,000 miles“Dt: the contact stated 1994, Ford van caught on fire on the freeway on 8-8-05. She was not having problems prior to the fire. The fire seemed to be electrical and originated under the hood. Updated 2/7/2006 - the consumer received recall 97v204000 on nov 13, 1997 for the transfer case/driveshaft but the dealer refused to make the repairs. This failure of this component could result in a fire. The consumer received information from NHTSA on two recalls for the vehicle. One was 99v028000 for the electrical wiring under the hood and the other one was 99v029000 for the ignition switch.”
NHTSA complaint #10132510, filed 2006-02, 100,000 milesRelated recalls
- 99V028000Feb 9, 1999Vehicle description: mini vans. Heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. The vehicle could…Covers: Ford Aerostar 1994–1995
- 99V029000Feb 9, 1999Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The…Covers: Ford Aerostar 1992–1997
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 1994 Ford Aerostar
44 complaintsTransmission and drivetrain
42 complaintsBrakes
25 complaintsEngine cooling
22 complaintsFuel system
20 complaintsSteering
20 complaintsBody and structure
16 complaintsSeat belts
12 complaintsVehicle speed control
12 complaintsSuspension
10 complaintsExterior lighting
9 complaintsTires
9 complaints
← All problems reported for the 1994 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