1995 Ford Aerostar Problems

What owners report

Complaints on this model year center on electrical trouble — ignition switch and wiring faults, occasional under-dash or door-panel smoke and fire, and headlights that cut out intermittently. Owners also describe brake vibration and grinding, transmission and torque converter wear, fuel smells and leaks from the tank area, and airbags that did not deploy in frontal impacts. Many reports come from vans with well over 100,000 miles, so age and wear color much of what is described.

1. 1
   Electrical system

   Ignition switch and under-dash wiring faults

   • 50 complaints (32%)
   • median 150,000 mi at 11.0 yrs old (3 state mileage, few)
   • 14 mention a crash, fire or injury
   • filed 1995–2007

   Owners describe the key turning all the way around in the cylinder, the van staying running with the key removed, or the engine failing to start with dash lights on. Others report burning-wire smells followed by smoke or flames behind the dash or in the driver's door, sometimes put out by hand; several say dealers could not diagnose it or had no parts for the ignition switch recall. Reported across a wide mileage range, including vans well past 100,000 miles; several complaints mention smoke appearing within seconds of starting the engine.

   Recall 99V029000Recall 99V028000

   What to check: Ask whether recall 99V029000 (ignition switch) and 99V028000 (fuel pump wiring harness) were completed and keep documentation. Check that the key turns smoothly, that the engine shuts off with the key removed, and look for scorched or spliced wiring under the dash and in the driver's door.

   2 excerpts from owner complaints in NHTSA records

   “We heard on the news that there is a recall involving Ford aerostars, model year 1995. The recall was for ignition switch shorting out. Can you e-mail me with information concerning this recall. 99v-029000. Thank you.”

   NHTSA complaint #704669, filed 1999-03

   “Dt: the caller said ignition failed. She said a year ago that the vehicle started by itself without a key. She stated that currently she had intermittent trouble starting the vehicle. The lights on the dashboard will come on but the vehicle will not start. Dealer said vehicle was not recalled. They will not help her for free. Manufacturer has not been contacted yet.”

   NHTSA complaint #10136919, filed 2005-10, 111,000 miles
2. 2
   Transmission and drivetrain

   Transmission and torque converter wear

   • 19 complaints (12%)
   • typically at 4.0 yrs old
   • 1 mention a crash, fire or injury
   • filed 1996–2001

   Owners report the automatic transmission stalling or failing to respond when accelerating, gradual loss of power, and fluid leaks followed by diagnosis of a worn torque converter or a transmission needing replacement. Some mention repeat transmission replacements, and owners of all-wheel-drive vans describe driveline resonance like the condition covered by a prior campaign. Mostly described on vans with high accumulated mileage; one owner reports failure at highway speed.

   Recall 97V204000

   What to check: Ask whether recall 97V204000 (transfer case and driveshaft on all-wheel-drive vans) was performed. Check transmission fluid condition and level, look for leaks, and test acceleration from a stop and at highway speed for delays or slipping.

   2 excerpts from owner complaints in NHTSA records

   “Continual loss of torque over last seven months. Dealer has always said it was the small engine until on 5-1-00 it refused to take off when stopped at a stop sign and had a leak coming from the transmission. Leak later stopped and a check of the fluid level showed it to be normal. Ron clark Ford checked it out today and said the torque converter and entire transmission was worn out and estimated replacement at $2,800 for a rebuilt transmission. …”

   NHTSA complaint #722293, filed 2000-05

   “Consumer received recall letter for transfer case/drive shaft,consumer called two dealers for an appointment. Both refused to order the part until they have a primary inspection. Recall letter stated that the vehicle must be serviced without delay.”

   NHTSA complaint #823791, filed 1998-05
3. 3
   Fuel system

   Fuel tank cracks, leaks and fuel odor

   Mentioned in 6 of 60 sampled complaints

   Owners describe a strong gasoline smell after refueling, a plastic fuel tank cracked at the top with fuel leaking, and cracked fuel straps or inlet fittings. A few report the engine cranking but not starting for several minutes after a fill-up. Reported mostly on vans above 150,000 miles, often noticed right after refueling.

   Recall 99V028000

   What to check: Smell around the van and look under it right after a fill-up for damp spots or odor, and inspect the tank top, straps and filler neck. Ask whether the fuel pump wiring recall 99V028000 applies to the vehicle and was done.

   2 excerpts from owner complaints in NHTSA records

   “When filling up the fuel tank, the engine turns over, but the van will not start until it sits for about 10 minutes. When taken to dealer, dealer stated that it would take about $800.00 to correct the problem. Owner does not agree with the findings, and continues to experience a problem when filling the tank.”

   NHTSA complaint #824531, filed 1998-06

   “There is a very strong smell of gasoline fumes in the van. About 2 years ago, the fuel line system was replaced by the dealership under warranty. Dealer is aware of the current situation, and stated to consumer that fuel line could not be replaced free of charge.”

   NHTSA complaint #826254, filed 1998-08
4. 4
   Brakes

   Brake vibration, grinding and rear brake wear

   • 8 complaints (5%)
   • typically at 1.2 yrs old
   • filed 1995–1999

   Complaints describe shaking or vibration through the front end when braking and turning at various speeds, and a grinding noise from the rear with rapid wear of rear shoes and hardware. One owner reports the ABS warning light staying on and the brakes locking up on dry pavement at low speed. Reported at various mileages with no clear pattern; several complaints describe repeat episodes after brake replacement.

   Recall 94V239000

   What to check: Drive and brake at moderate speed to feel for pedal or steering-wheel vibration, listen for rear grinding, and confirm the ABS lamp goes out after start. Have the rear brakes and brake lines inspected, including the spare tire carrier area.

   2 excerpts from owner complaints in NHTSA records

   “Anti-lock brake interior light stayed on the vehicle. While traveling at 35mph on dry pavement when applying the brakes to slow down, the system locked up, causing the vehicle to slide to a stop. Dealer has been contacted.”

   NHTSA complaint #832175, filed 1998-12

   “When applying force to the brake pedal consumer noticed a loud grinding noise from the rear end, resulting in excessive wear of the rear brakes shoes and pads/calipers.”

   NHTSA complaint #810268, filed 1997-03
5. 5
   Air bags

   Airbag did not deploy in a frontal impact

   • 10 complaints (6%)
   • typically at 4.9 yrs old
   • 9 mention a crash, fire or injury
   • filed 1995–2002

   Several owners report frontal or corner impacts where the driver's airbag did not deploy, sometimes with injuries described. Some complaints also mention the airbag light staying on after starting the van. Described in crashes at roughly 30-40 mph; no consistent mileage pattern in the sample.

   What to check: Confirm the airbag warning lamp comes on at startup and goes out. Ask whether the airbag system has been scanned for stored faults, and have any warning light diagnosed before purchase.

   2 excerpts from owner complaints in NHTSA records

   “1. Power steering belt sheared off which could cause loss of steering and control of vehicle. 2. Consumer was driving at approximately 30-35 MPH when it fishtaled and hit a pole head-on and then car on bumper. Upon impact, driver's side airbag did not deploy, resulting in injuries.”

   NHTSA complaint #837488, filed 1999-05

   “While driving at approximately 30mph & had a front end collision with another vehicle. Upon impact with other vehicle, driver's air bag failed to deploy. Was wearing seat belt. Some minor injuries. Vehicle declared totaled by insurance company.”

   NHTSA complaint #860841, filed 2000-04

Buying note. These vans are old enough that condition and service history matter more than the model itself. Check the ignition switch and fuel pump wiring recalls were completed, look for wiring repairs or scorch marks, and have the brakes, transmission and fuel tank inspected before buying.

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.