1991 Ford Aerostar
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Aerostar › 1991
These records cover every 1991 Ford Aerostar. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 1991 Ford Aerostar. Newest first.
Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
Risk and remedy
Risk
Loss of braking can result.
Remedy
Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
The ignition switch could experience an internal short circuit.
Risk and remedy
Risk
This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
Remedy
Dealers will replace the ignition switch.
When the automatic transmission shift lever IS placed in the park position, the park pawl does not always abut or engage the park gear.
Risk and remedy
Risk
Driver may believe the vehicle IS safely engaged in parkwhen the gear IS not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle IS started. All of these conditions canresult in a vehicle accident.
Remedy
Repair the transmission with a new park pawl.
Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
Risk and remedy
Risk
Vehicles would not comply with fmvss 210.
Remedy
Replace noncomplying sofa bar with bar that meets requirements.
Owner complaints
223 complaints23 involved a crash70 involved a fire25 injuries1 deaths
What owners report most
Latest complaints
- Electrical system
I had my starter replaced breaks and relay and it still having problems with the electrical system I cannot even turn on my headlights
- Unknown or other
Consumer requesting recall information on 1991 aerostar recall. *ts *nm
- Electrical system › Ignition › Switch
I owned a 1991 ford aerostar which burst into flames and was destroyed. I have been bounced around trying to get satisfactions but since there was an ongoing class action law suit have not received any compensation. the consumers wife noticed smoke coming from the steering column. The consumer…
I owned a 1991 ford aerostar which burst into flames and was destroyed. I have been bounced around trying to get satisfactions but since there was an ongoing class action law suit have not received any compensation. the consumers wife noticed smoke coming from the steering column. The consumer pulled over, ran to call the fire department, but by the time he returned the vehicle was fully engulfed in flames. updated 04/14/10.*jb
- Service brakes, hydraulic › Foundation components › Disc › Rotor
The front brake rotors warped, causing the vehicle to shimmy. dealership repaired the problem twice, but the consumer was still having the same problems. *Ak
- Power train › Automatic transmission
While driving 65 mph another motorist yelled at the consumer that the van was on fire. The fire appeared to be coming form the middle to the rear. Consumer pulled over, and noticed transmission fluid on the underside of the van. Consumer shut the engine off, and fire went out. A technician examined the van and stated that the transfer case needed to be replaced. Nhtsa recall campaign 99v094000 was issued. *ak
- Unknown or other
Transmission fluid entering coolant
- Engine and engine cooling · Power train · Unknown or other
1) replaced both head gaskets and bolts! 2) replaced extension housing gasket 3) replaced both valve cover gaskets, oil pan gasket, oil filter adapter o-rings
- Fuel system, gasoline · Service brakes, hydraulic
Brakes overheat on a curvey road
- Structure › Body › Door
Passenger side sliding door will no longer open. Vehicle has not been examined by dealer. nlm
- Service brakes, hydraulic › Foundation components › Drum
Consumer states that while driving down highway the rear brakes locked and caused a fire which melted the rear tires. consumer was travelling approx 65mph when the vehicle began to slow down and smoke began coming from the rear of vehicle.*jb.
- Equipment › Appliance › Air conditioner
I went to firestone in st. Joe, mo and had my air conditioning recharged after 9 years of driving my van. They told me that I needed to replace a hose on the front of the vechical and that they needed to then add freon to the system. That was in july 19, 2001. it didn't seem as cold as it had…
I went to firestone in st. Joe, mo and had my air conditioning recharged after 9 years of driving my van. They told me that I needed to replace a hose on the front of the vechical and that they needed to then add freon to the system. That was in july 19, 2001. it didn't seem as cold as it had before but it was ok. Then when I needed the air this summer I had none. They said that the hose that they installed they latter were told wouldn't hold the pressure (i think) but that now sence it was over 6 months they wouldn't or couldn't do anything. it cost me $304.07. They say that you people knew about this problem. What the hell IS going on?*ak
- Vehicle speed control
As soon as consumer shifted to drive, vehicle accelerated on its own, with tires spinning. Consumer applied brakes, then park brake, and shifted to neutral. Consumer accidently shifted to reverse and heard a loud clunking sound, vehicle came to a stop.*ak *jb
- Power train › Automatic transmission › Park/neutral start interlock switch
12 year old listening to radio moved shifter from passenger side. Van moved causing extensive leg injury to a person who was sitting behind vehicle. *Ak
- Exterior lighting › Headlights › Switch
I have been driving at night on several different occasions and had the headlights suddenly go out on me. The switch for the lights seems to be warm at these times. The heater seems to cause the switch to heat up and when it gets hot the lights go off. It may cause an accident one of these times if…
I have been driving at night on several different occasions and had the headlights suddenly go out on me. The switch for the lights seems to be warm at these times. The heater seems to cause the switch to heat up and when it gets hot the lights go off. It may cause an accident one of these times if it isn't fixed. I'm not sure if replacing the switch will help or if it will happen even with a new switch beacuse of the heat problem. Maybe the design of where the switch IS IS bad. Please advise me on what to do. Thank you.*ak
- Power train › Automatic transmission · Service brakes, hydraulic › Antilock/traction control/electronic limited slip
In damp or wet conditions rear brakes will lock up. Taken to dealer numerous times, insisted that this was normal for this vehicle. *Ak the transmission will not shift correctly. Up or down shifts between first and second gears IS very rough and sloppy. Also, when the weather IS cold the…
In damp or wet conditions rear brakes will lock up. Taken to dealer numerous times, insisted that this was normal for this vehicle. *Ak the transmission will not shift correctly. Up or down shifts between first and second gears IS very rough and sloppy. Also, when the weather IS cold the transmission refuses to shift into reverse or forward at times. The consumer stated that the transmission was rebuilt at 68,000 by the dealer and within a few months the same problems started up again. *yh
- Engine and engine cooling › Engine › Gasoline
While traveling at any speed or stopping at light vehicle would stall without any indication. Please provode further information. *ak
- Structure › Body › Tailgate › Hinge and attachments
The rear lift spring on the rear liftgate broke at the up posistion while unloading,causing the door to come slaming down on my back. *Ak
- Power train › Automatic transmission › Lever and linkage › Column shift
Four wheel drive/transfer case blew out and caught on fire. *Ak
- Service brakes, hydraulic › Foundation components
While driving the brakes failed resulting in vehicle collision with three injuries, upon expection of the brake pedal travel and reservoir (oshp units 977), no pressure on the pedal and no fluid in the reservoir (ohio traffic crash report) *mjs
- Electrical system › Wiring › Front underhood
This vehicle was driven for 20 minutes when a strong odor of plastic burning was smelled. This vehicle was parked when white smoke was noticed coming out from under the hood. A few seconds passed when the vehicle caught fire and was totally involved. this vehicle was totaled. *ak
- Vehicle speed control
While makeing a stop with foot depressing brake pedal vehicle started idling high. Please provide further information.*ak
- Electrical system › Alternator/generator/regulator
No summary listed for above vehicle. *ak
- Vehicle speed control › Accelerator pedal
As consumer tried to pull forward, engine revved and vehicle accelerated. Pedal was stuck all the way to floor, vehicle was stopped by concrete wall after about 40 ft. Vehicle totalled. *ak
- Exterior lighting › Brake lights
My wife has told me that on several occasions she has replaced the brake light on the right rear of her 1991 ford aerostar. I saw a ford aerostar minivan with a burned out brake light on my way to work today. Plus someone told me about an exact same problem involving a ford aerostar minivan. I have…
My wife has told me that on several occasions she has replaced the brake light on the right rear of her 1991 ford aerostar. I saw a ford aerostar minivan with a burned out brake light on my way to work today. Plus someone told me about an exact same problem involving a ford aerostar minivan. I have ruled out coincidence. What do you know about this problem.? Thanks I also listen to cartalk, with klick and klack, the tappett brothers. That was how I found out about your hotline.*ak
- Latches/locks/linkages › Hatchback/liftgate › Lock
The rear hatchback freezes (locked) closed and I am not able to open from either side. Which could prove dangerous in a crash situation. This IS my second aerostar with the same problem. The usefulness of the vihical IS cut by more than 75%
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Transfer cases and rear drive shaft
There is no summary currently available
- Parking pawl
When the automatic shift lever IS placed in the park position, the parking pawl does not always engage the park gear.this can lead to the vehicle jumping out of gear unintentionally and cause the vehicle to start rolling inadvertently
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 6091931Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock.
- 6090087Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems.
- 6090051Service tip information on revised oil pan gasket replacement procedure.
- 6089681Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses.
- 635982Some vehicles equipped with an automatic transmission and a 4.0L ohv engine may exhibit a noise / vibration, no drive, unusual noise during cranking or a no crank condition.
- 627752Some vehicles equipped with the 4.0L ohv engine may exhibit an engine noise which may be perceived by the customer as a piston / onnecting rod bearing knock.
- 623988Information regarding transmission fluid usage charts. *Slc
- 623944Some vehicles may exhibit heater core leaks. *Slc
- 622665On some vehicles, engine oil may continue to leak from the engine oil pan gasket area after an engine oil pan gasket repair has been performed.
- 616522Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system.
- 613340Experiencing a rapping or clanging noise when the steering wheel IS turned rapidly or when turning on a bumpy road surface.
- 613023This bulletin contains service tips when servicing any brake related roughness / pull concerns.
- 612203Information regarding the new transmission cooler flusher- service tip. *Mjs
- 608921Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock.
- 608431Information on the new flush and fill tool available through rotunda.
- 606460Experiencing a whine / buzz type noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump.
- 606420Ford motor company now recommends sae 5W-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year.
- 605573Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released.
- 604059Ford motor company has released a new electrical grease ( F8AZ - 19g208-aa ) to reduce the possibility of moisture corrosion at the terminals.
- 603724Mass air flow (maf)- sensor contamination- service tip.
- 603717Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles.
- 601341Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio.
- 601312Information on a buzzing or rattle noise from the exhaust system.
- 601290Information on tire company telephone numbers for customer assistance.
- 601269Announcing the ford oem air conditioning retrofit kit availability.
- 601238Information on a new transmission fluid usage chart.
- 601012The use of petroleum-based grease as a lubricant in servicing disc brakes IS no longer acceptable.
- 601010Recommended guidelines for towing behind recreational vehicles.
- 600586Front and rear bumpers made of xenoy plastic have had the conductive primer removed from service parts.
- 51987Fuel economy- customer expectations versus vehicle usage.
- 51945Fluid- transmission fluid usage charts.
- 51689Frame- rivet replacement with bolts- service tips.
- 515594.0L equipped vehicles may experience temperature gauge fluctuation that may be accompnied with a thumping noise or feel in the coolant hoses with the engine at normal operating temperature.
- 514824.0L equipped vehicles may experience temperature gauge fluctuation that may be accompanied with a thumping noise or feel in the coolant hose with the engine at normal operating temperature.
- 51002Brakes - brake service - service tips.
- 50997Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip.
- 50940Windshield and interior glass - fog/film.
- 50908Torque converter - leak test procedure - service tip.
- 50905Wiring - electrical diode identification and service replacements.
- 46478The use of petroleum-based grease as a lubricant in servicing disc brakes IS no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. If petroleum-based grease IS used to lubricate any part of the disc brake system, it could cause rubber parts to swell if lubricant contacts the rubber material.
Every Ford Aerostar model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.