1994 Ford Aerostar: problems, recalls and reliability
5 recalls and 257 owner complaints on record; the weakest area is electrical system (21% of complaints); the 1996 model year looks more trouble-free.
Data updated weekly · latest recall Mar 2006
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 257 owner complaints filed with NHTSA for this exact model year.
“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”Owner report · Electrical System · Jun 2008
“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”Owner report · Electrical System · Jan 2008
“All electronics on steering column don't work. Air bag system flashes 3-2. No airbag (presumably), cruise control or horn function. *tr”Owner report · Electrical System · Oct 2007
Show 7 more owner reports
“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”Owner report · Wheels · Jun 2006
“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”Owner report · Electrical System · Aug 2005
“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”Owner report · Air Bags · Oct 2004
“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”Owner report · Air Bags · Jun 2004
“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”Owner report · Steering · Mar 2004
“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”Owner report · Structure · Aug 2003
“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”Owner report · Suspension · May 2003
When filing, owners marked a crash in 22 of these complaints and injuries in 33 - self-reported to NHTSA, not verified accident statistics.
Recalls - 5 campaigns
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 LOSS OF VEHICLE DRIVE CAN RESULT.
Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
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 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
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.
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.
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.
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.
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 1994 Ford Aerostar reliable?
NHTSA has 257 owner complaints and 5 recall campaigns on record for the 1994 Ford Aerostar. The most complained-about area is electrical system (21% of complaints).
At what mileage do 1994 Ford Aerostar problems usually appear?
Half of the complaints that mention mileage were filed at 109,089 miles or less.
Does the 1994 Ford Aerostar have open recalls?
5 recall campaigns have been issued, the latest concerning power train:transfer case (4-wheel drive). 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.