1991 Ford Aerostar: problems, recalls and reliability
4 recalls and 223 owner complaints on record; the weakest area is electrical system (29% of complaints).
Data updated weekly · latest recall Apr 1998
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 223 owner complaints filed with NHTSA for this exact model year.
“I had my starter replaced breaks and relay and it still having problems with the electrical system I cannot even turn on my headlights”Owner report · Electrical System · May 2017
“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”Owner report · Service Brakes, Hydraulic · Jan 2004
“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”Owner report · Engine And Engine Cooling · Nov 2002
Show 7 more owner reports
“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.”Owner report · Service Brakes, Hydraulic · Jul 2002
“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”Owner report · Vehicle Speed Control · Jun 2002
“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”Owner report · Equipment · May 2002
“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”Owner report · Power Train · May 2002
“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”Owner report · Exterior Lighting · Dec 2001
“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”Owner report · Structure · Aug 2001
“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”Owner report · Electrical System · Jun 2001
When filing, owners marked a crash in 23 of these complaints and injuries in 25 - self-reported to NHTSA, not verified accident statistics.
Recalls - 4 campaigns
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
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.
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.
Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.
How other years compare
Check your exact Aerostar by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 1991 Ford Aerostar reliable?
NHTSA has 223 owner complaints and 4 recall campaigns on record for the 1991 Ford Aerostar. The most complained-about area is electrical system (29% of complaints).
At what mileage do 1991 Ford Aerostar problems usually appear?
Half of the complaints that mention mileage were filed at 127,705 miles or less.
Does the 1991 Ford Aerostar have open recalls?
4 recall campaigns have been issued, the latest concerning seat belts:front:anchorage. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.