1994 Ford Aerostar
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Aerostar › 1994
These records cover every 1994 Ford Aerostar. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 1994 Ford Aerostar. Newest first.
Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006…
Risk and remedy
Risk
Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Remedy
Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.
Vehicle description: MINI vans. heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. the vehicle could experience a loss of power and become immobilized and the fuel gauge may be erratic.
Risk and remedy
Risk
Heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. the short circuit could also have the potential for a vehicle fire.
Remedy
Dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.
Vehicle description: MINI vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the B2 (battery), A2 (accessory), and P1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
Risk and remedy
Risk
This can cause over heating and the potential for a vehicle fire.
Remedy
Dealers will install a jumper harness with a relay which will re-route and activate all A2 accessories through the relay.
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.
Vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or…
Risk and remedy
Risk
This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Remedy
Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Owner complaints
257 complaints22 involved a crash28 involved a fire33 injuries4 deaths
What owners report most
Latest complaints
- Air bags · Seat belts
Airbag (code 13 and 51) lights flashing
- Electrical system
Van had been driven for approximately two hours or so, around the local city communities. Van had been parked for approximately five minutes, when neighbors notified me of fire. Intense fire was coming from driver's side/windshield/ignition/front seat area, eventually consuming entire interior of…
Van had been driven for approximately two hours or so, around the local city communities. Van had been parked for approximately five minutes, when neighbors notified me of fire. Intense fire was coming from driver's side/windshield/ignition/front seat area, eventually consuming entire interior of van. Norfolk fire department responded within five minutes, or so, station only about 150 yards from my residence. Fire was extinguished within five minutes or so, but the van was completely consumed by fire and totally destroyed by then. Van was junked/salvaged. Paid only $100.00 for salvage/junk/towing, etc. Prior to this incident, I had no problems with my van. Van only had 93000 miles. Had purchased new from freedoms ford in norfolk, va. Informed by associate that I should report this "fire hazard/problem," because other 1994 ford aerostar vans have experienced similar "fire problems/incidents/reports," and the like. Please inform me of what actions I need to take to recoup some monetary value for this "fire incident," etc. My vehicle paperwork was burned/destroyed in the fire. However, the norfolk fire department did make an "official fire report/record" of the incident, etc. Also, minor damage was done to the aluminum siding of my house from the vehicle fire. *tr
- Electrical system
Had the clock ring repaired (year 2000)due to the airbag light stayed on. Now the airbag light stays on ,there IS no horn and the cruise control doesnt work. There has to be a recall for this safety problem. *tr
- Electrical system › Wiring › Front underhood · Fuel system, gasoline
We were beginning to experience loss of power. The fuel pump and filter was changed. We are still getting intermittent loss of power, but what my concern IS that I saw a recall on nhtsa: 99v028000. I was made aware of this recall when I viewed an episode of cops where an aerostar's electrical…
We were beginning to experience loss of power. The fuel pump and filter was changed. We are still getting intermittent loss of power, but what my concern IS that I saw a recall on nhtsa: 99v028000. I was made aware of this recall when I viewed an episode of cops where an aerostar's electrical system caused a fire in the engine compartment. I called ford in temecula calif and now they have no record of any recalls for this year of aerostar 1994 I do have kids and I would like to know what safety matters remain on this van. *Tr
- Air bags · Electrical system · Electrical system › Horn · Vehicle speed control
All electronics on steering column don't work. Air bag system flashes 3-2. no airbag (presumably), cruise control or horn function. *tr
- Electrical system › 12v/24v/48v battery · Electrical system › Alternator/generator/regulator · Electrical system › Ignition › Module · Electrical system › Starter assembly › Solenoid · Exterior lighting › Brake lights · Exterior lighting › Headlights · Exterior lighting › Tail lights · Power train › Clutch assembly › Bell housing · Service brakes, air › Disc › Pads · Steering › Linkages › Tie rod assembly · Structure › Frame and members › Underbody shields · Suspension › Front · Suspension › Front › Shock absorber · Suspension › Front › Springs › Coil springs · Suspension › Rear › Springs › Coil springs · Wheels › Lugs/nuts/bolts/studs · Wheels › Rim
Front coil springs snapped, had to replaced with reading spring works, they had to send the specks to chicago. My ford aero star 4 wheel drive & 4.0 V6 IS not available from after market. The only option IS to buy new or used ford springs which are made in china. The local ford dealer admits…
Front coil springs snapped, had to replaced with reading spring works, they had to send the specks to chicago. My ford aero star 4 wheel drive & 4.0 V6 IS not available from after market. The only option IS to buy new or used ford springs which are made in china. The local ford dealer admits replacing coil & leaf springs on several models. Midas was so busy replacing ford springs, they could not set up an appointment to install springs even if I had the springs. *tr
- Electrical system › Ignition
Car was parked in driveway, untouched, for at least 24 hours. Fire erupted about 7:00 am. Flames were coming through the drivers side windshield. Seemed to be electrical in nature. Car IS a total loss. Car IS completely original (no electric alterations). Car had been to the dealer within the last 2 years so any recall work should have been done. *tr
- Steering › Steering wheel/handle bar
The seams in the steering wheel ooze black goo and form dime sized pools around the inside center where the airbag IS packed ...the dealer said just buy a cover but it continues to leak as a new steering wheel would be very costly due to airbag, I worry if airbag will deploy correctly in a crash. *jb
- Tires › Tread/belt
1994 ford aerostar tire blew (firestone dayton quadra SE). *ts the tread separated from the tire. *nm
- Air bags · Electrical system › Horn · Vehicle speed control › Cruise control
Dt: contact stated that the air bag light on the dashboard flashed on and off. The cruise control and the horn will not work. The problem started without warning. He was told by the dealer the air bag will not work as long as the light on the dashboard was on. Also, the dealer told him he had a…
Dt: contact stated that the air bag light on the dashboard flashed on and off. The cruise control and the horn will not work. The problem started without warning. He was told by the dealer the air bag will not work as long as the light on the dashboard was on. Also, the dealer told him he had a broken wire in the steering wheel. He has not had it repaired yet. The air bag problem was not covered under warranty or recall. Therefore, e the manufacturer will offer no free remedy. *Ak
- Electrical system › Wiring › Front underhood · Engine and engine cooling › Engine
Dt: the contact stated 1994, ford van caught on fire on the freeway on 8-8-05. She was not having problems prior to the fire. The fire seemed to be electrical and originated under the hood. *Ak *jb updated 2/7/2006 - the consumer received recall 97v204000 on nov 13, 1997 for the transfer…
Dt: the contact stated 1994, ford van caught on fire on the freeway on 8-8-05. She was not having problems prior to the fire. The fire seemed to be electrical and originated under the hood. *Ak *jb updated 2/7/2006 - the consumer received recall 97v204000 on nov 13, 1997 for the transfer case/driveshaft but the dealer refused to make the repairs. this failure of this component could result in a fire. The consumer received information from nhtsa on two recalls for the vehicle. one was 99v028000 for the electrical wiring under the hood and the other one was 99v029000 for the ignition switch. *nm
- Visibility › Windshield wiper/washer › Switch/wiring
Windshield wipers fail to function unless lights are on high beam or washer sequence IS started. *jb
- Air bags
Consumer's vehicle was involved in a head on collision while going through an inner section between 25-30 mph. Upon impact, driver's side air bag failed to deploy. driver sustained chest injuries from the seat belt. Manufacturer wanted to send a factory representative to investigate the cause of the failure.*ak
- Air bags · Electrical system › Horn · Service brakes, air › Antilock › Abs warning light · Service brakes, hydraulic › Brake fluid low warning › Lamp
Three days after I have the vans wireing done because of a recall, my horn stopped working and the air bag light started flashing and my brake lights started staying on. I called jim wilson ford who did the repairs I was told by the head man at the dealership that it was not there falt and I would have to pay to have it fixed. everything worked fine until they did the recall work.*ak
- Electrical system › Wiring › Interior/under dash · Fuel system, gasoline › Delivery › Fuel pump · Steering › Column
The accessories in my dash and steering column are shorting out, and I saw that there was a recall on that. the problem IS that the recall does not include when my van was made. I don't care why I just want to be able to drive my kids to school and back and not have my van catch on fire. we have…
The accessories in my dash and steering column are shorting out, and I saw that there was a recall on that. the problem IS that the recall does not include when my van was made. I don't care why I just want to be able to drive my kids to school and back and not have my van catch on fire. we have been through that already with a different vehicle. also, the fuel pump IS acting up andi was told it seems as though it IS shorting out!. again not the right month but I have the same problems so the way I see it IS that ford messed up and should fix the problem, period. I plan to continue to follow this and to right to my local government. the safety of my family should not be determined as to how loudly people complain, it seems as though the vehicles that are covered were the greatest risk to the company. *la
- Structure › Frame and members
Spare tire fell-off, with out any warning, from its mounting underneath the van. we were lucky that this happened in a parking lot and the van we just parked. There was a rattle during driving, but stopped when going slow or stopped. *la
- Power train › Automatic transmission
Consumer states that the gear shift can be pushed down without applying the brake. Dealer notified.*ak
- Air bags › Frontal
Consumer states that a front collision occurred and the air bag deployed on her face. Since them she had a respiratory problem. *Ak
- Seat belts › Front › Buckle assembly
Driver's seatbelt will not stay fastened. cause IS unknown. please provide any further information.*ak
- Suspension › Rear › Springs
Failure of right rear coil spring causing explosive tire deflation. failure occurred at the end of the spring coating- corrosion present, but hidden by factory coating of spring. *jb
- Power train › Automatic transmission
Automatic transmission failure - transmission falls out of gear. *jb
- Tires
The right rear tire blew out. *jb
- Air bags
Date IS approximate. 1994 ford aerostar rear ended at stop light hard enough to break 7X19 cable holding spare tire, and send vehicle into car in front of it with enough force to break radiator and ac radiator. air bag did not deploy. approximatly 3 months after back from repairs, the airbag…
Date IS approximate. 1994 ford aerostar rear ended at stop light hard enough to break 7X19 cable holding spare tire, and send vehicle into car in front of it with enough force to break radiator and ac radiator. air bag did not deploy. approximatly 3 months after back from repairs, the airbag light started blinking occasionly. this continued getting worse until it blinked constantly, also the horn was intermittentaly operational. I checked your "search complaints" section and see several people have had the same problem even without the accident. I had the vehicle repaired and it was the clock spring as several people state in the complaints section. in fact this must be common due to when I called the dealership that did the original repairs they didn't even listen to all the information on the problem and said "it sounds like the clock spring and takes about 2 hours to repair." then quoted a price, only missing the price quote by the amount of tax added to the bill! please research this, if nothing else look at your own system under airbags, horn, and speed controls! doesn't take a bean counter to see there IS a problem with this "safety" system!!!!!!!*jb
- Electrical system › Ignition › Switch · Electrical system › Wiring › Interior/under dash
The wiring harness in my steering colume IS defective. This will be the second time in 6 yrs that this has had to be replaced. The harness controlls the airbage, horn and cruise controll. Also the igition switch IS faulty, the key can be removed while the vehicle IS running
- Air bags › Frontal
The vehicle hit a tree, and the air bags failed to deploy. *jb the consumer slid on a patch of ice and hit a tree in center of the bumper. *scc *jb
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Luggage compartment door drops abruptly
Odi has identified 30 incidents resulting in minor to moderate personal injuries that have been caused by abrupt door drops over the approximately eight - twelve year period of product usage and exposure (1991-1995 to 2003).most of the injury incidents appear to have been caused by a fracture of the gas filled lift…
Odi has identified 30 incidents resulting in minor to moderate personal injuries that have been caused by abrupt door drops over the approximately eight - twelve year period of product usage and exposure (1991-1995 to 2003).most of the injury incidents appear to have been caused by a fracture of the gas filled lift assist cylinder mounting stud.stud fractures have occurred randomly over time and do not exhibit any apparent trend relating to date of vehicle production or time-in-service (exposure).the odi closing report summarizes the details of this investigation.
- Transfer cases and rear drive shaft
There is no summary currently available
- Transfer cases and rear driveshaft
There is no summary currently available
- Fuel sender assembly fires
There is no summary currently available
- Fuel sender assembly fires
Owners allege that failure of the fuel pump/sender connector results in short circuit that has resulted in vehicle fires.symptoms include erratic fuel gauge operation, , smoke from the dash on the driver's side near the steering column (fuel pump fusible link) and passenger side (fuel pump inertia cutoff switch)…
Owners allege that failure of the fuel pump/sender connector results in short circuit that has resulted in vehicle fires.symptoms include erratic fuel gauge operation, , smoke from the dash on the driver's side near the steering column (fuel pump fusible link) and passenger side (fuel pump inertia cutoff switch), intermittent stall and no start concerns, and a burning odor. Several incidents have resulted in damage to plastic fuel tubes and/or fuel supply/return tubes.
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.
- 10008580Lamp-brake-invadvertent disabling of brake shift interlock.
- 10003748New transmission cooler flusher - service tips. 2003 escort and super duty f series included.
- 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.
- 6090082Information for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement.
- 6090051Service tip information on revised oil pan gasket replacement procedure.
- 6089681Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses.
- 3057200Unknown
- 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.
- 625715Brake shift interlock.*jb
- 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.
- 616508Special field action regarding revised waranty information.
- 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.
- 607372Information regarding transfer case rear housing and driveshaft replacement.
- 606508Conditions with the brake lamps inadvertently disabling the brake shift interlock.
- 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.
- 605562Subject regarding the availability of hub-mount brake rotor machining equipment.
- 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.
- 603695Experiencing a " buzzing " or " rattling " noise from the exhaust system.
- 601341Experiencing a whining / buzzing noise in the speakers of the entertainment radio or two-way radio.
- 601290Information on tire company telephone numbers for customer assistance.
- 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.
- 601009Service tip information regarding elimination of sanding rotors and drums.
- 601003Hub-mount brake rotor machining equipment from rotunda IS now approved for warranty and service use.
- 600586Front and rear bumpers made of xenoy plastic have had the conductive primer removed from service parts.
- 54075Experiencing a "thumping" noise or tempeature gauge fluctation with some vehicles.
Every Ford Aerostar model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.