1996 Ford Aerostar Transmission and drivetrain Problems
- Complaints
- 12about this part
- Share
- 12%of 104 total for the year
- Median mileage
- 160,000miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 12 complaints about the transmission and drivetrain of the 1996 Ford Aerostar, 12% of the 104 complaints for this model year. Where a mileage was given, the median is 160,000 miles. 1 recall campaign on record is filed under a similar system.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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“The contact owns a 1996 Ford Aerostar. While driving approximately 50 MPH the front drivers side tire began to vibrate. The vehicle was taken to an independent mechanic. The technician stated the transfer case would have to be replaced. The vehicle was not repaired. Nhtsa recall campaign id number: 97v204000 (power train:transfer case (4-wheel drive)) may be related to the failure. The manufacturer was made aware of the failure and stated the VIN was not included. The approximate failure mileage was 160,000.”
NHTSA complaint #10425204, filed 2011-09, 160,000 miles“The contact stated the vehicle was taken to a tire dealer for replacement of the tires. After the tires were replaced and vehicle was being driven home at 45mph, the vehicle hesitated as if the gears were not changing properly. The vehicle was returned to the tire dealer who determined the drive shaft was loose. The dealer recommended the vehicle not be used until the drive shaft was welded and the universal joint was replaced.”
NHTSA complaint #10156967, filed 2006-05, 214,000 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“Nhtsa recall 97v204000, manufacturer 97s83, transfer case; dealer's letter was received in march, and in april when contacted the dealer again, they didn't have the parts, when contacted again, the parts were in, but could not be located.”
NHTSA complaint #824067, filed 1998-06Related 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 1996 Ford Aerostar
23 complaintsBrakes
18 complaintsElectrical system
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