1996 Ford Aerostar Problems

What owners report

Owners of the 1996 Aerostar most often describe cracks developing in the spokes or lug areas of the factory alloy wheels, and brakes that fade, warp rotors or lose pedal response. Drivetrain reports center on the all-wheel-drive transfer case and driveshaft, and a smaller group describes airbags that did not deploy in a frontal impact. Many reports come from vans well past 100,000 miles, though a handful describe wheel cracks at much lower mileage.

1. 1
   Wheels

   Cracks in alloy wheel spokes and rims

   • 22 complaints (21%)
   • median 124,000 mi at 10.5 yrs old (3 state mileage, few)
   • filed 1999–2007

   Owners describe cracks in the spokes, between spokes, or around the lug nut holes of the original 14x6 aluminum wheels, sometimes on three or four wheels at once. Several say they felt a wobble or heard a loud noise at speed and found one or more spokes already broken, while others found the cracks during a routine inspection with the van parked. Complaints say dealers and Ford generally declined to replace the wheels or offered no explanation, and many owners switched to steel rims at their own expense. Mileage appears on only a few of these complaints, from about 58,000 to 125,000 miles, and most reports give no mileage at all.

   What to check: Inspect each alloy wheel closely for hairline cracks in the spokes and around the lug holes, including the spare, and ask whether the van still has its original aluminum rims or has already been switched to steel.

   2 excerpts from owner complaints in NHTSA records

   “On 9/17/02 the right front alloy wheel cracked while on vacation. We were unable to travel in it. It was expensive and difficult to replace. On 2/1/03 (also out of town) the left back alloy wheel cracked. We are searching for a replaement. Our mechanic told us this should not happen and must be a manufacturing defect. There are several similair complaits please evaluate as it could cause a severe accident.”

   NHTSA complaint #10005362, filed 2003-02, 124,500 miles

   “While doing periodic inspection of my vehicle noticed 2 cracked spokes on rear right 14x6 alloy rim. The crack is all the way through . Local Ford dealer was not helpful at all. This tire has not impacted anything as the Ford dealer eluded to, and I feel this is a definite safety issue, and the cracks may be due to a manufacturing defect. Any help in this matter would be appreciated. Ford should acknowledge there is a problem and quit blaming the consumer.”

   NHTSA complaint #10118477, filed 2005-04
2. 2
   Brakes

   Brake fade, warped rotors and caliper trouble

   • 15 complaints (14%)
   • typically at 2.4 yrs old
   • 3 mention a crash, fire or injury
   • filed 1997–2002

   Complaints describe the brake pedal going to the floor or giving no response, longer stopping distances, and in a few cases a collision after the brakes did not slow the van. Others report repeated rotor warping and vibration when braking, with dealers turning or resurfacing the rotors without a lasting fix. One owner reports calipers that crumbled when the brakes were taken apart after a long downhill drive, and another describes a pin in the parking brake handle breaking so the van rolled. Mileages quoted in the complaint text range from roughly 12,000 to about 58,000 miles, and several failures followed repeated braking on downhills or slow-speed stops.

   What to check: Ask for brake service records, check pedal feel and rotor condition on a long test drive, and have the calipers and parking brake mechanism inspected before buying.

   2 excerpts from owner complaints in NHTSA records

   “As promised, I'm back. Major brake failures at 32,518, 55,638, and recently at 58, 700. I checked your site through the cartalk website and found 12 brake problems reported out of 79. I am not the only owner whose family is at risk. Mosy recently, the brake pedal bottomed out two consecutive times at slow speed. The passengers in the car said they smelled heated brakes. I believe the calipers may be dragging, overheating the brakes. I cannot duplicate the problem. …”

   NHTSA complaint #730166, filed 2000-09

   “My brakes failed after an extended downhill drive--although not an unusual circumstance. In taking apart the disk brakes, my mechanic discovered that the calipers had become brittle (over time from heat) and they crumbled in his hands. The pads had worn down but still were within an acceptable thickness (but at the low end). The rotor was normal. The mechanic believes that there is a design flaw in these brakes resulting from a rotor that is too thin (normally) and as a result does not absorb heat well from the pads. …”

   NHTSA complaint #725691, filed 2000-07
3. 3
   Transmission and drivetrain

   Transfer case and driveshaft problems (AWD)

   • 8 complaints (8%)
   • median 160,000 mi at 10.6 yrs old (3 state mileage, few)
   • filed 1998–2011

   On all-wheel-drive vans, owners report the transfer case breaking or failing while driving, leaving the van unable to move or shift, with shops quoting a replacement transfer case. Some describe a loose driveshaft or universal joint, a thumping or hesitation, and a seal leak at the transfer case. Several owners say they were told their van was not covered by the transfer case recall, or that the recall work did not resolve the problem when it was done. Reported mileages vary widely, from a seal leak noted under 30,000 miles to transfer case replacement around 81,000, 160,000 and 214,000 miles.

   Recall 97V204000

   What to check: On an all-wheel-drive van, ask whether recall 97V204000 was performed and keep the paperwork, and have the transfer case and driveshaft checked for leaks, looseness or clunking.

   2 excerpts from owner complaints in NHTSA records

   “I bought a used 1996 Ford Aerostar awd van from a used car dealer about 10 months ago. I had some problems with the van immediately but the dealer declined responsibility. Today I have learned that the transfer case in the van needs, minimally, repair or total replacement. I have already replaced a ball joint for $320, which the used car dealer said he had checked and there was no problem. We are retirees without a huge income and so we decided to investigate whether Ford was in some way responsible. …”

   NHTSA complaint #10067683, filed 2004-04, 81,000 miles

   “Similar to safety recall # 97s83 for which service was performed, but affecting front shaft and transfer case instead of rear. Had seal leak on front transfer case under 30k miles warranty. Transfer case bearing failure on front drive shaft in transfer case ruined transfer case at a cost of $1,985.00 to repair. This vehicle has been treated very well, with no heavy loads or towing of trailers.”

   NHTSA complaint #701665, filed 1998-12
4. 4
   Air bags

   Airbags not deploying in frontal impacts

   • 6 complaints (6%)
   • median 140,000 mi at 8.9 yrs old (1 states mileage, few)
   • 6 mention a crash, fire or injury
   • filed 1996–2004

   Owners describe frontal and rear-end collisions in which the driver or passenger airbags did not deploy, including one van that was struck head-on while stationary and one multiple-vehicle pile-up with damage across the whole front of the van. Complaints say Ford was contacted and, in the owners' view, did not explain why the airbags stayed folded. One report also notes a locked sliding door coming open in the same impact. Impacts are described as roughly 15 to 50 mph, and only one of these reports gives a mileage, about 140,000 miles.

   What to check: Ask whether the airbags or crash sensors have ever been serviced or replaced, and confirm the airbag warning light comes on and then goes out at start-up; a pre-purchase scan can look for stored airbag codes.

   2 excerpts from owner complaints in NHTSA records

   “In a multiple car pile-up, with speeds between 35 and 50 MPH the driver's airbag in our van (vehicle number #3 of 4 involved) did not deploy. Our vehicle was damaged across the entire front and the entire back bumpers (grill, hatch...). My daughter was examined by a physician and missed some work. If the airbag had deployed she should have received some protection.”

   NHTSA complaint #10091293, filed 2004-09, 140,000 miles

   “Van involved in head on collision while sitting still. Speed from other vehicle estimated at 40 MPH. Air bag failed to deploy upon collision. Impact was to extent of frame being knocked out of line. Please describe details.”

   NHTSA complaint #8015295, filed 2002-08
5. 5
   Electrical system

   Ignition switch failure, stalling, dash smoke

   • 10 complaints (10%)
   • median 107,000 mi at 11.2 yrs old (3 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1996–2017

   Complaints describe the ignition cylinder coming out with the key, all electrical power cutting out and the engine stalling, and smoke or a burning smell from under the dash near where the steering column meets it. One owner reports a burning odor followed by the engine quitting and a fire in the firewall area. Several owners say Ford told them their van was not covered by the ignition switch recall even though it showed the same symptoms, and at least one was told recall parts were unavailable. Mileage appears on a few of these reports, between about 81,000 and 115,000 miles, while the smoke and fire reports give no mileage.

   Recall 99V029000

   What to check: Ask whether recall 99V029000 was completed on this van, watch for any burning smell or smoke at the base of the dash, and request the electrical repair history.

   2 excerpts from owner complaints in NHTSA records

   “I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major Ford dealer (brandon Ford), and they are refusing to help me. I called Ford customer service and he said my VIN is not listed for a recall, but yet had no answer for me when I asked why is my vehicle not on the recall list, when it is in the group of vehicles that were recalled and that are catching on fire while driving down the road. …”

   NHTSA complaint #11019124, filed 2017-08, 107,000 miles

   “The consumer received a recall letter concerning ignition switch failure on 03/99. On 10/21/03 consumer stopped, parked vehicle, took key out of the ignition, and ignition cylinder came out.”

   NHTSA complaint #10044646, filed 2003-10, 81,300 miles

Buying note. These are high-mileage vans now, so the priorities are the wheels and the brakes: check the alloy rims for spoke cracks and budget for brake work if records are thin. On an all-wheel-drive example, confirm the transfer case recall was done and have the driveline inspected before you commit.

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.