1996 Ford Aerostar: problems, recalls and reliability
6 recalls and 104 owner complaints on record; the weakest area is wheels (21% of complaints).
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 104 owner complaints filed with NHTSA for this exact model year.
“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.”Owner report · Structure · Jul 2019
“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.....”Owner report · Electrical System · Aug 2017
“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.”Owner report · Power Train · May 2011
Show 7 more owner reports
“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.”Owner report · Wheels · Oct 2007
“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”Owner report · Electrical System · Dec 2006
“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.”Owner report · Power Train · May 2006
“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.”Owner report · Wheels · Mar 2006
“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”Owner report · Wheels · Apr 2005
“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”Owner report · Electrical System · Jan 2005
“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”Owner report · Wheels · Nov 2004
When filing, owners marked a crash in 9 of these complaints and injuries in 7 - self-reported to NHTSA, not verified accident statistics.
Recalls - 6 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. 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.
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."
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.
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.
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."
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.
Specifications
Factory options offered for the 1996 model year, decoded from the NHTSA vPIC database. Individual vehicles have one of each.
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 1996 Ford Aerostar reliable?
NHTSA has 104 owner complaints and 6 recall campaigns on record for the 1996 Ford Aerostar. The most complained-about area is wheels (21% of complaints).
At what mileage do 1996 Ford Aerostar problems usually appear?
Half of the complaints that mention mileage were filed at 119,500 miles or less.
Does the 1996 Ford Aerostar have open recalls?
6 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.