1996 Ford Aerostar Brakes Problems
- Complaints
- 18about this part
- Share
- 17%of 104 total for the year
- Median mileage
- —not reported
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 18 complaints about the brakes of the 1996 Ford Aerostar, 17% of the 104 complaints for this model year. 4 of these say a crash was involved, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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“On april 19, 1999, quality of napa located at 1823 soscol ave, napa, 94559, performed our 30,000 mile service which in our Ford maintenance schedule book includes inspection of disc brake system and drum brake system. On april 19th, our mileage was 34,712.5 and quality signed off on the maintenance schedule for both the 30,000 & 35,000 mile service. On or about may 17th, 1999 our brakes failed at 35,597 miles, and caused us to take our van to Ford for troubleshooting. Ford charged us over $500 to replace the brakes. …”
NHTSA complaint #706692, filed 1999-05“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. We owned an Aerostar previously and had no such brake problems, certainly not a pad replacement at 32,000. …”
NHTSA complaint #730166, filed 2000-09“While driving, vehicle will jerk forward. This is caused by front rotors warping extremely. Dealer contacted. The brake pads are barely worn. Consumer was advised by Ford that the warranty had expired and there was nothing they could do. Consumer feels the rotors warped prematurely.”
NHTSA complaint #8014952, filed 2002-07“Brake rotors are wearing, and when the consumer applies the brakes, the vehicle will jerk and become hard for the consumer to control. The dealer was notified. The consumer states that this is a result of warped front brake disc. (Ford won't pay)”
NHTSA complaint #8018497, filed 2002-09Brakes: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2000 | 1 | 17% |
| 1997 | 7 | 11% |
| 1996 | 18 | 17% |
| 1995 | 16 | 10% |
| 1994 | 25 | 10% |
| 1993 | 59 | 16% |
| 1992 | 58 | 18% |
| 1991 | 34 | 15% |
| 1990 | 27 | 14% |
| 1989 | 20 | 8% |
| 1988 | 9 | 5% |
| 1987 | 4 | 4% |
| 1986 | 1 | 2% |
Other parts of the 1996 Ford Aerostar
23 complaintsElectrical system
12 complaintsTransmission and drivetrain
12 complaintsSteering
9 complaintsAir bags
6 complaintsLatches, locks and linkages
6 complaintsTires
5 complaintsBody and structure
4 complaintsVehicle speed control
4 complaintsEquipment
3 complaintsSeats
3 complaintsEngine cooling
2 complaints
← All problems reported for the 1996 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