1996 Ford Aerostar
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Aerostar › 1996
These records cover every 1996 Ford Aerostar. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 1996 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. 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.
The certification labels on the involved vehicles has incorrect rear tire inflation pressure designations. this does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."
Risk and remedy
Risk
Incorrect inflation pressures could cause premature wear of the rear tires. .
Remedy
Owners will be provided with correct certification labels and instructions for installing these labels. dealers can install this label if the owner so desires.
When in the secondary latched position, the driver door latches may open when subjected to transverse loads less than that specified in fmvss no. 206, "door locks and door retention components."
Risk and remedy
Risk
The driver's door, when closed only to the secondary latched position, may not sustain a 1,000 pound transverse load.
Remedy
Dealers will inspect and, if necessary, replace the driver door latch.
Owner complaints
104 complaints9 involved a crash4 involved a fire7 injuries
What owners report most
Latest complaints
- Structure › Body · Wheels
Condensed version: @ 70mph posted speed limit goodyear allegra touring tire exploded like a 1/4 stick of dynamite and almost cost me my life if my reactionary time had been any slower. 3 other tires same leaking through sidewall goodyear decorative gills on same this has not resolved. Seller has…
Condensed version: @ 70mph posted speed limit goodyear allegra touring tire exploded like a 1/4 stick of dynamite and almost cost me my life if my reactionary time had been any slower. 3 other tires same leaking through sidewall goodyear decorative gills on same this has not resolved. Seller has not resolved and refuses though goodyear said to replace before the main issue of the left front driver tire exploding at 70 mph, . Litigation IS next step if amicable resolution can not be had. Contact has been extensive with goodyear to no results.
- Electrical system
I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major ford dealer (brandon ford), and they are refusing to help me. I called ford customer service and he said my vin IS not listed for a recall, but yet had no answer for…
I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major ford dealer (brandon ford), and they are refusing to help me. I called ford customer service and he said my vin IS not listed for a recall, but yet had no answer for me when I asked why IS my vehicle not on the recall list, when it IS in the group of vehicles that were recalled and that are catching on fire while driving down the road. Over 887,000 were recalled for fire related problems, but they refuse to even look at mine. So, can I keep driving it? I don't know if it was a one time thing, or what.....
- Seat belts
12/6/2014 @ 18:20 c.s.t. to whom it may concern, (hopefully a supervisor or director) the drivers side seat belt floor clasp fails. I releases the seat belt while driving. After two or three times of re-hooking the seat-belt to the hold down clasp bolted through floor board of the vehicle, it…
12/6/2014 @ 18:20 c.s.t. to whom it may concern, (hopefully a supervisor or director) the drivers side seat belt floor clasp fails. I releases the seat belt while driving. After two or three times of re-hooking the seat-belt to the hold down clasp bolted through floor board of the vehicle, it will no longer accept and hold the seat belt in place. this has happened to both of my vehicles, the 1993 occurred at appx. 190,000 miles and when I contacted ford about this safety issue and failure of the seat belt to remain clasped, they simply said, it IS an older vehicle and you have to purchase the entire seat belt assembly for over $500.00...[xxx]. this IS a safety issue...and ford needs to replace the hold down clasp which IS bolted through the floor board free of charge. Labor and part free. if I had been attempting to avoid an accident or was in an accident and that belt let loose, I might be dead. this should never happen. My 1976 ford torino never had this problem, nor the other vehicles referenced, nor any other vehicle I have ever owned. This IS a safety and driver safety which needs to be addressed, and no matter the age of the vehicle, it IS a safety feature mandated by all states motor vehicle laws to be engaged at all times while driving. If the item IS defective by design, and as in my case, it arbitrarily and without notice of its imminent failure, fails with no pressure on it, it needs to be a recalled item. I also suspect that ford IS still purchasing from the same supplier and if this IS true, then all subsequent seat belt hold down clasps will fail likewise at the 6 - 9 year range, without notice and expose ford to wrongful death suits due to mechanical defects in those seat belt hold down clasps. I am cutting and pasting a copy of this formal complaint so that I have a record of its submission today december 6, 2014 @ 18:20 c.s.t. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6). *tr
- Power train
TL* 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…
TL* 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.
- Wheels
Tl*the contact owns a 1996 ford aerostar. while driving 50 mph, the contact heard a loud roaring sound. she stopped the vehicle and noticed that the rear passenger wheel spokes failed. the wheel was replaced with a spare tire. there was no damage to the tire or vehicle. the wheel was inspected…
Tl*the contact owns a 1996 ford aerostar. while driving 50 mph, the contact heard a loud roaring sound. she stopped the vehicle and noticed that the rear passenger wheel spokes failed. the wheel was replaced with a spare tire. there was no damage to the tire or vehicle. the wheel was inspected by the repair shop and they stated that the wheel was defective. the wheels were the original wheels for the vehicle. the powertrain was unknown. the current and failure mileages were 58,000.
- Electrical system › Ignition › Switch
Dt*: the contact stated while the vehicle was being driven 30 mph, all power failed and the engine stalled. the stalling has also occurred at higher speeds and while the vehicle was immobile. a fuse connected to the battery cables blew. when the fuse was replaced, the engine would restart. The…
Dt*: the contact stated while the vehicle was being driven 30 mph, all power failed and the engine stalled. the stalling has also occurred at higher speeds and while the vehicle was immobile. a fuse connected to the battery cables blew. when the fuse was replaced, the engine would restart. The vehicle was taken to the service dealer. the contact was informed the vehicle was not included in recall # 99v029000, for the electrical ignition switch due the vin even thought vehicle had the same problems. the manufacturer was not notified.*ak
- Power train › Driveline › Driveshaft · Power train › Driveline › Universal joint
Dt*: 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…
Dt*: 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.
- Wheels
Dt*: the contact stated the front wheels on the vehicle cracked. this was noticed from a visual inspection by the contact. the manufacturer was alerted and stated the wheels cracked under stress from the vehicle.
- Wheels › Rim
While doing periodic inspection of my vehicle noticed 2 cracked spokes on rear right 14X6 alloy rim. The crack IS all the way through . Local ford dealer was not helpful at all. This tire has not impacted anything as the ford dealer eluded to, and I feel this IS a definite safety issue, and the…
While doing periodic inspection of my vehicle noticed 2 cracked spokes on rear right 14X6 alloy rim. The crack IS all the way through . Local ford dealer was not helpful at all. This tire has not impacted anything as the ford dealer eluded to, and I feel this IS a definite safety issue, and the cracks may be due to a manufacturing defect. Any help in this matter would be appreciated. Ford should acknowledge there IS a problem and quit blaming the consumer.*ak
- Electrical system › Wiring
The vehicle was parked in front of the residence and it caught on fire. driver called the fire department to extinguish the fire. no injuries. vehicle was towed and totaled by the insurance company. *Ak
- Wheels › Rim
A few years ago we noticed that 2 of the aluminum wheels on our 1996 aerostar were cracked . we took the vehicle to the ford motor co.service department where we were living at the time the service manager contacted the regional manager, who agreed to pay half of the replacement costs. since…
A few years ago we noticed that 2 of the aluminum wheels on our 1996 aerostar were cracked . we took the vehicle to the ford motor co.service department where we were living at the time the service manager contacted the regional manager, who agreed to pay half of the replacement costs. since that time, 2 additional aluminum wheels have cracked. we have been told that ford will not replace these. I feel that this IS definitely a safety issue, and that the cracks are due to a manufacturing defect, which ford motor co. Should acknowledge and correct. wheels are not a normal wear item.*ak
- Air bags
In a multiple car pile-up, with speeds between 35 and 50 mph the driver's airbag in our van (vehicle number #3 of 4 involved) did not deploy. our vehicle was damaged across the entire front and the entire back bumpers (grill, hatch...). my daughter was examined by a physician and missed some work. if the airbag had deployed she should have received some protection.*ak
- Tires › Tread/belt
While driving 70 mph, the rear driver side tire tread separated. The consumer managed to pull over to change tire. The dealership was notified, but did not resolve the problem. Please provide more information. Size#21570r14 dot#hyhy4fa229. *nm
- Power train › Transfer case (4-wheel drive)
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…
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. we learned that a recall for transfer cases was issued in 1998 so my wife called ford, where she was, of course, told that our vehicle was not involved in the recall. I want to know how I can learn if this IS true or whether I can make ford responsible for this major malfunction. they say they are not in any way responsible!!!! over the years, I have owned many, many vehicles and have never had a transmission problem before. because of the transfer case, my front tires are bald and I need two tie rod ends after the transfer case repair. my vehicle will not pass inspection and I do not know how I will pay for all of these repairs. I also still have two years' car payments left!!!*ak
- Electrical system › Ignition
The consumer received a recall letter concerning ignition switch failure on 03/99. On 10/21/03 consumer stopped, parked vehicle, took key out of the ignition, and ignition cylinder came out. *ak
- Wheels › Rim
My 1996 ford aerostar has 14X6 aluminum allow wheel rims. the rims have 7 triangular slots and 7 wide/flat "spokes". one of these rims IS cracking. the crack IS progressing from one spoke to another. I have stopped driving the vehicle all together. after almost a month of searching for a…
My 1996 ford aerostar has 14X6 aluminum allow wheel rims. the rims have 7 triangular slots and 7 wide/flat "spokes". one of these rims IS cracking. the crack IS progressing from one spoke to another. I have stopped driving the vehicle all together. after almost a month of searching for a used replacement rim I have found out that I am not the only one with this problem. I suspected that this may be the case when I could not find any on-line company that had these in stock (used or new). today I spoke with a woman at ackerwheels.com and learned that this rim can only be purchased from the dealer. she warned me that if I ordered one from the dealer to look it over carefully for cracks. I asked her if this was a common problem. she said it was and that I should not expect ford to recall it. I believe that all of my other three rims are now suspect. what can you do? *jb
- Wheels › Rim
One of seven spokes on left front alloy wheel/rim IS cracked all the way through. right rear wheel/rim IS starting to crack (showing on top surface). local ford dealer said there are no recalls on this item. one local used auto parts distributer said he was not allowed to sell this type of rim…
One of seven spokes on left front alloy wheel/rim IS cracked all the way through. right rear wheel/rim IS starting to crack (showing on top surface). local ford dealer said there are no recalls on this item. one local used auto parts distributer said he was not allowed to sell this type of rim because of potential liability suits. another used parts distributer said he gets several request a month for the same rim. based on the number of complaints, ford should recall the rims before failures/fatalities. *jb
- Tires › Tread/belt
I noticed a "pinhole" on my viper GT tires, contacted the dealer where I purchased them, they told me that they were not on a recall list but would replace them for a "difference" cost. I researched the internet and discovered that 1-2 years earlier cooper (the manufacturer) gad a recall on a…
I noticed a "pinhole" on my viper GT tires, contacted the dealer where I purchased them, they told me that they were not on a recall list but would replace them for a "difference" cost. I researched the internet and discovered that 1-2 years earlier cooper (the manufacturer) gad a recall on a similar issue. The dot number of the tires that had on my van were as follows: 30 hy udn2802 - this tire had no noticable pinhiole 30 hy udn2401 - pinhole with visible wire threads visible 30 hy udn2402 - pinhole with visible wire threads visible 30 hy udn3001 - pinhole but no visible wires showing yet. *ak
- Tires › Tread/belt
While driving, the tire experienced tread separation. *ak *jb
- Wheels › Rim
On 9/17/02 the right front alloy wheel cracked while on vacation. We were unable to travel in it. It was expensive and difficult to replace. On 2/1/03 (also out of town) the left back alloy wheel cracked. We are searching for a replaement. Our mechanic told us this should not happen and must be a manufacturing defect. There are several similair complaits please evaluate as it could cause a severe accident.
- Service brakes, hydraulic › Foundation components › Disc › Rotor
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. *ak the consumer states that this IS a result of warped front brake disc. (ford won't pay) *scc
- Air bags › Frontal
Van involved in head on collision while sitting still. speed from other vehicle estimated at 40 mph. air bag failed to deploy upon collision. impact was to extent of frame being knocked out of line. please describe details. *Ak
- Service brakes, hydraulic › Foundation components › Disc › Rotor
While driving, vehicle will jerk forward. This IS caused by front rotors warping extremely. Dealer contacted.*ak 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. *jg
- Tires
These 2 tire failures occurred under normal driving cirucumstances on a vehicle that IS regularly maintained at the firestone service center that installed the tires. firestone has denied claim of vehicle repair from the tire separation incident on june 16, 2002, saying the 'tire was improperly…
These 2 tire failures occurred under normal driving cirucumstances on a vehicle that IS regularly maintained at the firestone service center that installed the tires. firestone has denied claim of vehicle repair from the tire separation incident on june 16, 2002, saying the 'tire was improperly inflated for an undetermined time period'. their own people inspected the tires 40 days prior, the time of the 1ST tire separation, claiming tires to be worthy, properly inflated etc. we firmly believe that an investigation into these tires must happen, if it isnt already underway. this was a potentially dangerous situation that fortunately did not end tragically, other than dollars spent out of our pocket. please take serious note to our circumstance, it can not be common of tires that 2 would separate in 40 days on a regularly maintained vehicle on a clear highway and speeds under normal highway speed limits. after the first tire failure, the service center manager stated that the 'tire had separated and failed'. after the second separation, the same manager had the same statement for the second tire. they ultimately were willing to replace all 4 tires with a bridgestone product, for us, that was unacceptable, we choose to take our business elsewhere (clearly, not an issue for the nhtsa). though, what IS of great concern to us IS the lack of urgency on the part of local firestone and corporate firestone that there could potentially be a serious problem with a product they sell.thank you in advance for your time, your prompt response, and your consideration.*ak
- Wheels
Aluminium wheels have cracks in them. Dealer notified.*ak *tt
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
- Transfer cases and rear driveshaft
There is no summary currently available
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.
- 10008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application.
- 10003748New transmission cooler flusher - service tips. 2003 escort and super duty f series included.
- 10000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340.
- 6091931Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock.
- 6090873Locks failed. Yd
- 6090538Information regarding camshaft position (cmp) sensor alignment tool chart. *Mjs
- 6090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes.
- 6090184Information on replacing and / or repairing malfunctioning (door, ignition and decklid) locks.
- 6090136During extreme cold ambient temperatures and under certain driving conditions, moisture in the crankcase may enter the pcv system, freeze and cause presure in the engine crankcase. The pcv fitting in the upper intake manifold may freeze or the fresh air line may become blocked. It IS also possible, but less likely, that ice may build up on the throttle plate or the throttle body and cause throttle sticking.
- 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.
- 637922Some vehicles built prior to 9/15/2001 may exhibit low line pressure readings while in drive, no 2ND gear, no 3RD gear, no engine braking in manual 1ST and slipping shifts and / or delayed engagements.
- 637755Some vehicles may exhibit a no 1-2 upshift, no 2-3 upshift, a no engine braking condition in manual 1 or diagnostic trouble code p0732 (gear 2 incorrect ratio) or p0733 (gear 3 incorrect ratio).
- 635998Low line pressure reading at wide open throttle (wot), slipping shifts and / or delayed engagements with possible diagnostic trouble codes p0732, p0733, p1762 set on vehicles built before 12/1/2001.
- 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.
- 630515Engine oil system priming procedures, service tips for reports of premature engine failure.
- 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.
- 613621Information regarding pump alignment tools. **Mr
- 613348When replacing an internal wiring harness on 4r44e/4r55e transmissions built before 11/30/95 with a new harness, the fluid pan must be replaced also. Failure to change over or convert the fluid pan may result in a transmission fluid leak or a damaged wiring harness.
- 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.
- 606461Ford motor company has released a private labeled material to be used for iron particle / acid rain service repairs.
- 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.
- 606419Subject regarding door trim panel replacement - service tip.
- 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.
Every Ford Aerostar model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.