1991 Ford AEROSTAR problems and owner complaints
Explore the records behind recurring owner reports.
Key facts
133 owner complaints analyzed
3 distinct recall campaigns
127,705 mi median reported failure mileage
Scope: 1991 model year. Data snapshot: . 2 complaints include usable failure mileage.
Most common problems
Electrical System:Ignition:Switch is the most frequently named component, appearing in 13 of 133 complaints (9.8%). A complaint can name multiple components.
| Topic | Matching reports | Share of complaints |
|---|---|---|
| Braking behavior | 26 | 19.5% |
| Transmission and shifting | 16 | 12.0% |
| Electrical and battery issues | 15 | 11.3% |
| Steering behavior | 10 | 7.5% |
| Engine operation | 2 | 1.5% |
| Fuel system concerns | 1 | 0.8% |
Topic matches use published keyword rules. They describe mentions, including negations or comparisons, and do not confirm a diagnosis. Read the matching rules.
Component breakdown
Number of unique complaints naming each component. Top eight shown.
| Category | Count |
|---|---|
| Electrical System:Ignition:Switch | 13 |
| Power Train:Automatic Transmission | 13 |
| Power Train:Automatic Transmission:Park/Neutral Start Interlock Switch | 12 |
| Vehicle Speed Control | 9 |
| Service Brakes, Hydraulic:Foundation Components:Master Cylinder | 8 |
| Equipment:Appliance:Air Conditioner | 7 |
| Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip | 7 |
| Electrical System:Wiring:Front Underhood | 5 |
Electrical System:Ignition:Switch: 13; Power Train:Automatic Transmission: 13; Power Train:Automatic Transmission:Park/Neutral Start Interlock Switch: 12; Vehicle Speed Control: 9; Service Brakes, Hydraulic:Foundation Components:Master Cylinder: 8; Equipment:Appliance:Air Conditioner: 7; Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip: 7; Electrical System:Wiring:Front Underhood: 5
Reported problems by failure mileage
Complaint counts in mileage bands. These are not failure rates per vehicle or mile.
| Category | Count |
|---|---|
| Under 25,000 | 0 |
| 25,000 to 49,999 | 0 |
| 50,000 to 74,999 | 0 |
| 75,000 to 99,999 | 0 |
| 100,000 to 149,999 | 1 |
| 150,000 and above | 1 |
Under 25,000: 0; 25,000 to 49,999: 0; 50,000 to 74,999: 0; 75,000 to 99,999: 0; 100,000 to 149,999: 1; 150,000 and above: 1
100,000 to 149,999 miles has the most reports with usable mileage (1). 131 complaints have missing, zero or invalid mileage.
Complaints over time
Year the complaint was filed, not the vehicle model year or incident year. The snapshot year is partial.
| Category | Count |
|---|---|
| 1995 | 50 |
| 1996 | 38 |
| 2000 | 16 |
| 2001 | 16 |
| 2002 | 5 |
| 2004 | 5 |
| 2005 | 1 |
| 2006 | 1 |
| 2017 | 1 |
1995: 50; 1996: 38; 2000: 16; 2001: 16; 2002: 5; 2004: 5; 2005: 1; 2006: 1; 2017: 1
Pattern summary
Electrical System:Ignition:Switch leads the component reports. Braking behavior appears in 26 complaint narratives. Transmission and shifting appears in 16 complaint narratives. Electrical and battery issues appears in 15 complaint narratives. Use these patterns to inspect individual reports and prepare questions for a mechanic.
Calculated from recorded counts. An AI narrative has not been published for this selection.
Complaint evidence
Examples provide context, not a representative sample or a verified diagnosis.
Owner report 10068880 · 2004-01-15 (January 15, 2004)
BRAKES OVERHEAT ON A CURVEY ROAD
Owner-reported narrative. Look up ODI 10068880 at NHTSA ↗
Owner report 10087370 · 2004-08-06 (August 6, 2004)
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-reported narrative. 150,000 miles reported. Look up ODI 10087370 at NHTSA ↗
Owner report 10071270 · 2004-01-15 (January 15, 2004)
TRANSMISSION FLUID ENTERING COOLANT
Owner-reported narrative. 105,410 miles reported. Look up ODI 10071270 at NHTSA ↗
Owner report 10073700 · 2004-05-17 (May 17, 2004)
WHILE DRIVING 65 MPH ANOTHER MOTORIST YELLED AT THE CONSUMER THAT THE VAN WAS ON FIRE. THE FIRE APPEARED TO BE COMING FORM THE MIDDLE TO THE REAR. CONSUMER PULLED OVER, AND NOTICED TRANSMISSION FLUID ON THE UNDERSIDE OF THE VAN. CONSUMER SHUT THE ENGINE OFF, AND FIRE WENT OUT. A TECHNICIAN EXAMINED THE VAN AND STATED THAT THE TRANSFER CASE NEEDED TO BE REPLACED. NHTSA RECALL CAMPAIGN 99V094000 WAS ISSUED. *AK
Owner-reported narrative. Look up ODI 10073700 at NHTSA ↗
Owner report 10994317 · 2017-06-11 (June 11, 2017)
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-reported narrative. Look up ODI 10994317 at NHTSA ↗
Owner report 480789 · 1995-01-30 (January 30, 1995)
HEADLIGHT SWITCH WIRING SHORTED OUT, CAUSING A FIRE. *AK
Owner-reported narrative. Look up ODI 480789 at NHTSA ↗
Owner report 10120979 · 2005-05-16 (May 16, 2005)
I OWNED A 1991 FORD AEROSTAR WHICH BURST INTO FLAMES AND WAS DESTROYED. I HAVE BEEN BOUNCED AROUND TRYING TO GET SATISFACTIONS BUT SINCE THERE WAS AN ONGOING CLASS ACTION LAW SUIT HAVE NOT RECEIVED ANY COMPENSATION. THE CONSUMERS WIFE NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER, RAN TO CALL THE FIRE DEPARTMENT, BUT BY THE TIME HE RETURNED THE VEHICLE WAS FULLY ENGULFED IN FLAMES. UPDATED 04/14/10.*JB
Owner-reported narrative. Look up ODI 10120979 at NHTSA ↗
Owner report 800327 · 1996-07-31 (July 31, 1996)
AFTER DEALER REPLACED IGNITION SWITCH UNDER RECALL CAMPAIGN, 1 MONTH LATER EXPERIENCED SMOKE COMING FROM UNDERNEATH STEERING COLUMN AND IGNITION SWITCH HOUSING, RESULTING BURNT FRONT WIRING HARNESS AND SWITCH ASSEMBLY.*AK
Owner-reported narrative. Look up ODI 800327 at NHTSA ↗
Owner report 729454 · 2000-08-29 (August 29, 2000)
A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP REPLACING WHOLE REAR AXLE ASSEMBLY AND DIFFERENTIAL FROM SALVAGE YARD MYSELF BECAUSE IT WAS MUCH LESS EXPENSIVE THAN WHAT THE REPAIR PLACE WANTED. TRANSMISSION BEGAN SLIPPING DURING ACCELERATION. AFTER A COUPLE DAYS IT QUIT MOVING THE VEHICLE COMPLETEL…
Owner-reported narrative. Look up ODI 729454 at NHTSA ↗
Owner report 899347 · 2001-11-21 (November 21, 2001)
WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION. *AK
Owner-reported narrative. Look up ODI 899347 at NHTSA ↗
Owner report 508324 · 1996-09-04 (September 4, 1996)
FUEL LEAK CAUSED ENGINE FIRE.
Owner-reported narrative. Look up ODI 508324 at NHTSA ↗