1996 Ford AEROSTAR problems and owner complaints

DURING A BRAKE INSPECTION AT A TIRE STORE, IT WAS POINTED OUT THAT THE ORIGINAL ALUMINUM WHEELS WERE CRACKED. TWO OF THE LARGE SPOKES ON ONE WHEEL WERE CRACKED THROUGH. ONE OTHER WAS CRACKED BUT NOT ALL THE WAY THROUGH. I CALLED WENDLE FORD WHO HAD SOLD ME THE CAR. THEY SAID IT WASN'T A WARRANTY ITEM AND THEY HAD NEVER HEARD OF SUCH A FAILURE BEFORE. I TOOK THE CAR TO THE DEALER SHIP TO SHOW THEM THE CRACKED WHEELS. THEY THEN TOLD ME THAT I WAS THE SECOND PERSON TODAY (JANUARY 14, 2000) WHO HAD THE SAME PROBLEM WITH CRACKED WHEELS ON AN A…

Owner-reported narrative. Look up ODI 717531 at NHTSA ↗

MY BRAKES FAILED AFTER AN EXTENDED DOWNHILL DRIVE--ALTHOUGH NOT AN UNUSUAL CIRCUMSTANCE. IN TAKING APART THE DISK BRAKES, MY MECHANIC DISCOVERED THAT THE CALIPERS HAD BECOME BRITTLE (OVER TIME FROM HEAT) AND THEY CRUMBLED IN HIS HANDS. THE PADS HAD WORN DOWN BUT STILL WERE WITHIN AN ACCEPTABLE THICKNESS (BUT AT THE LOW END). THE ROTOR WAS NORMAL. THE MECHANIC BELIEVES THAT THERE IS A DESIGN FLAW IN THESE BRAKES RESULTING FROM A ROTOR THAT IS TOO THIN (NORMALLY) AND AS A RESULT DOES NOT ABSORB HEAT WELL FROM THE PADS. HE HAS OBSERVED THE SA…

Owner-reported narrative. Look up ODI 725691 at NHTSA ↗

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 CA…

Owner-reported narrative. 81,000 miles reported. Look up ODI 10067683 at NHTSA ↗

WAS TRANSMISSION ON A TECH LIST FOR REPAIRS OR RECALL LIST FOR PROBLEMS AT HIGHWAY SPEED AND LOW SPEED PROBLEMS. *AK( DOT NUMBER: TIRE SIZE: 215/75/14 )

Owner-reported narrative. Look up ODI 721200 at NHTSA ↗

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 …

Owner-reported narrative. 107,000 miles reported. Look up ODI 11019124 at NHTSA ↗

THE METAL PORTION OF POWER STEERING FLUID RETURN HOSE AND ONE OF THE METAL LINES TO THE POWER STEERING GEAR BOX/ACTUATOR ARE MOUNTED IN SUCH A MANNER THAT THEY RUB TOGETHER AND OVER TIME RUB AWAY AT THE METAL AND DEVELOP LEAKS THAT CAUSE THE POWER STEERING FLUID TO LEAK OUT CAUSING A CATASTROPHIC FAILURE OF THE POWER STEERING. THE ONLY INDICATION OF THIS FAILURE IS WHINING COMING FROM THE ENGINE COMPARTMENT.*AK

Owner-reported narrative. Look up ODI 740741 at NHTSA ↗

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-reported narrative. 115,000 miles reported. Look up ODI 10175900 at NHTSA ↗