1994 Ford Aerostar Transmission and drivetrain Problems
- Complaints
- 42about this part
- Share
- 16%of 257 total for the year
- Median mileage
- 120,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 42 complaints about the transmission and drivetrain of the 1994 Ford Aerostar, 16% of the 257 complaints for this model year. Where a mileage was given, the median is 120,000 miles. 4 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.
“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“While driving in the smoky mountains in nc the transmission overheated and poured out transmission fluid. The van began to smoke and I pulled over in a dangerous place. I decided to turn around (also in dangerous place) I went back to cherokee, nc and a mechanic said this was a common problem for areostars. He said many people get ripped off by untrustworthy mechanics. While traveling over the mountains we saw three other areostars with the same problem. Two were being towed by wreckers. Areostar owners need to be notified of this problem. …”
NHTSA complaint #747646, filed 2001-07“In march of 1995 I took custody of my three nieces, due to their mother's addiction to meth. At that point we owned a Ford excort, which we traded in on the Ford Aerostar in may of that year, with approximately 18,000 miles. When the van reached approx. 55,000 miles my wife was driving in phoenix and the transfer case went out, while she was driving around 35 MPH. Since the component was under warranty pioneer Ford replaced the component, and this only took them 5 to 6 weeks. In august of 1998 the transfer case went out again, with approx. …”
NHTSA complaint #711394, filed 1999-09“This Aerostar van has been an extremely good vehicle until we recently started having problems with the front transfer case. We received a recall in 1998 for the transfer case, although all that was replaced was the rear case. About 1 year later we started having leakage from the front transfer case. We returned the truck to the dealer and they stated that this was not part of the recall, but we would have to have this crack repaired. We went to several transmission repair facilities and they indicated that they see this crack in the front case frequently in the Aerostar van. …”
NHTSA complaint #717622, filed 2000-01“The tranfer case heated up and separated from the transmission in the process the transmssion was cracked and replaced, three times by the manufacturer. The transfer case was recalled (97v-204) by the manufacturer after the transmission had failed three times.”
NHTSA complaint #8010438, filed 2002-05Related recalls
- 97V204000Nov 13, 1997Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing…Covers: Ford Aerostar 1992–1997
Transmission and drivetrain: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2000 | 2 | 33% |
| 1999 | 3 | 43% |
| 1997 | 9 | 14% |
| 1996 | 12 | 12% |
| 1995 | 22 | 14% |
| 1994 | 42 | 16% |
| 1993 | 68 | 18% |
| 1992 | 75 | 24% |
| 1991 | 49 | 22% |
| 1990 | 37 | 19% |
| 1989 | 31 | 12% |
| 1988 | 13 | 7% |
| 1987 | 15 | 13% |
| 1986 | 7 | 13% |
Other parts of the 1994 Ford Aerostar
69 complaintsAir bags
44 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 31, 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