1997 Ford Aerostar Problems

What owners report

Complaints on this model year cluster around the speed-control and throttle linkage, cracked aluminum wheel rims, and electrical/ignition problems, with a smaller but consistent set of transmission and brake reports. Many filings reference recall campaigns, and a recurring theme is dealers saying a problem was not covered by the recall or could not be reproduced. Mileage in the sample ranges widely, from about 24,000 to 180,000 miles, so these are mostly older, high-mileage vehicles.

1. 1
   Vehicle speed control

   Throttle sticking or unintended acceleration

   • 9 complaints (14%)
   • median 56,500 mi at 6.5 yrs old (2 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1997–2010

   Owners describe the van revving up on its own, either while parked or while driving, and in some cases accelerating when the brake is applied or when cruise control is engaged. Several complaints describe the throttle not responding to the pedal or the pedal needing repeated presses before the vehicle moves. Others report that cruise control would not disengage with the brake or the switch, and that the vehicle had to be slowed by braking and shutting off the ignition. A few mention a sticking throttle linkage or a cable end coming loose from the accelerator pedal. Reported across a wide mileage range, from around 48,000 to 65,000 miles up to higher-mileage vans, both around town and at highway speed under cruise control.

   Recall 00V425000

   What to check: Ask whether the accelerator cable recall (00V425000) was performed and inspect the cable and throttle linkage for kinks, fraying or sticking. Check that cruise control disengages with the brake pedal before relying on it.

   2 excerpts from owner complaints in NHTSA records

   “Note: I wish I had found this site years ago. I could not get past fords brick wall to speak to an engineer! 1. 1997 Aerostar - accelerator pedal was pressed down quickly to pass (2 lane highway). 2. Now in the left lane, not far ahead of passed the car - I experrienced a complete loss of power - hard right over to soft shoulder - avoided an oncoming head on collision - l just missed the car being passed by inches and stopped. The crimped end of cable to the carburator had released from the accelerator pedal. 3. …”

   NHTSA complaint #10350538, filed 2010-08, 48,000 miles

   “When accelerating consumer had to depress the gas pedal several times to get the vehicle to move. When the vehicle moved the throttle got stuck, and revved very high. Dealer informed the consumer that the throttle linkage had a sticking problem.”

   NHTSA complaint #10049874, filed 2003-12, 65,000 miles
2. 2
   Electrical system

   Ignition switch and dash electrical shorts

   • 18 complaints (29%)
   • median 122,746 mi at 14.2 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1998–2020

   Complaints describe smoke coming from the steering column near the ignition switch or from behind the dash near the climate controls, along with blown fuses, a dead instrument panel and a fuel pump that would not run with the key. Owners describe intermittent problems that dealers could not reproduce, and some report the ignition switch recall work was done without resolving the symptoms. Battery drain and a horn that sounds on its own are also reported. Appears on vans from moderate to high mileage, often as an intermittent fault that is hard to duplicate at the dealer.

   Recall 99V029000

   What to check: Ask whether the ignition switch recall (99V029000) was completed, and check that the instrument panel, horn and fuel pump behave normally with the key. Look for signs of melted or discolored wiring around the column and dash.

   2 excerpts from owner complaints in NHTSA records

   “The electrical system involving the horn continually fails. The horn regulary goes off while the vehicle is not running. I have replaced both horns, the low and high frequency. I have replaced the horn relay. With each replacement, the horn burns out because it is operated for extended periods because it is set off by something in the system. This usually occurs at night.”

   NHTSA complaint #719234, filed 2000-02

   “My 1997 Ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. …”

   NHTSA complaint #10129732, filed 2005-07
3. 3
   Transmission and drivetrain

   Transmission shudder, harsh shifting and seal leaks

   • 8 complaints (13%)
   • median 108,746 mi at 5.7 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1999–2008

   Owners describe the transmission balking, jerking or feeling as if it is trying to engage two gears at once, sometimes nearly stalling the van. Others report fluid leaks from the front seal, and overdrive that drops out as soon as the throttle is opened. Some complaints describe harsh or unexpected downshifts while driving, and a few concern transfer case noise on all-wheel-drive vans after recall repairs. A service bulletin covers power train control module programming procedures. Reported from moderate mileage up to around 132,000 miles, typically after years of use rather than in the first few thousand miles.

   Recall 97V2040001 related service bulletin

   What to check: Check transmission fluid level and color and look for leaks at the front seal. On all-wheel-drive vans, confirm whether the transfer case recall (97V204000) applies and was completed, and listen for unusual noise while driving.

   2 excerpts from owner complaints in NHTSA records

   “My transmission developed a bad leak in the front seal. I paid to have the transaxle removed and the seal replaced. The fluid was changed as well as the filter and then shortly afterwards the cars overdrive stopped working. It will shift into overdrive but it will shift right back out when I step on the gas even the least little bit. I could not afford to have it fixed so I put it in drive and drove it for about 3 weeks and yesterday I was doing about 60 and the car shifted into second gear for no reason and then right back into thrid. …”

   NHTSA complaint #10070676, filed 2004-01, 132,000 miles

   “Need to know were to start to get all the problems on my van taken care of all the recalls, of power train the electrical and whatever else was reported to me on my report of the recalls on this 1997 areostar van thank you maryjean.”

   NHTSA complaint #10222447, filed 2008-03
4. 4
   Brakes

   Brake noise, dragging rear brakes and soft pedal

   • 10 complaints (16%)
   • median 132,000 mi at 6.9 yrs old (1 states mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1997–2004

   Owners report grinding or loud noise from the rear wheels when turning or braking, and excessive front pad and rotor wear that they link to the rear brake self-adjusters. Some describe the pedal going to the floor intermittently with the ABS light coming on, and dealers being unable to find the cause. Others report rear brake heat and related wear on axle seals and bearings. Reported across various mileages, generally on older, higher-mileage vans with original or long-serving brake hardware.

   What to check: Have the brakes inspected front and rear, including the rear self-adjusters, and ask about service history. Check pedal feel and whether the ABS light stays off during a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Consumer experiencing intermittent brake failure. When consumer applied brakes, the pedal would go to the floor without indication or brake pedal would go to the floor. Abs senor light would come on would come on while consumer continued pumping the brakes for vehicle to stop. Dealer notified and unable to resolve the problem.”

   NHTSA complaint #828006, filed 1998-09

   “Consumer experiencing excessive wear of the front brake pads and shoes/ rotors due a malfunction within the rear brake adjusters. Consumer has contacted the dealer, dealer has replaced parts. Please provide any further information on other complaints.”

   NHTSA complaint #827610, filed 1998-09
5. 5
   Wheels

   Cracked aluminum wheel rims

   • 5 complaints (8%)
   • median 136,000 mi at 7.0 yrs old (3 state mileage, few)
   • filed 2000–2009

   Owners report cracks appearing in the spokes of the factory aluminum wheels, sometimes in several places on one rim, without any impact or road hazard. In some cases the crack was found during inspection, and owners describe concern about losing a wheel. One complaint notes a front tire wearing faster than the others despite repeated balancing. Mostly reported between roughly 74,000 and 180,000 miles, usually found during inspection or routine service rather than after an impact.

   What to check: Inspect each wheel rim closely for cracks around the spokes, especially on higher-mileage vans, and ask whether any rims have been replaced.

   An excerpt from owner complaints in NHTSA records

   “Consumer took vehicle to the dealership for inspection, and mechanic determined that two front rims cracked. Consumer called Ford motor company and said that they won't address the problem because it's not on warranty or recall. However, consumer replaced both rims.”

   NHTSA complaint #10059385, filed 2004-03, 74,000 miles

Buying note. On a vehicle this old, condition and service records matter more than the model year itself. Confirm which of the open recalls were actually performed, then have a mechanic check the wheels for cracks, the throttle and cruise control linkages, and the brakes and transmission before buying.

Summary written with AI from a sample of 40 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.