Ford AEROSTAR recalls by model year

Reported: 1986-01-22 (January 22, 1986) · Model years: 1986

THERE MAY BE INADEQUATE WELDING IN SOME UNDERBODY STRUCTURAL AREAS, INCLUDING THOSE AT THE REAR SUSPENSION ATTACHMENTS, WHICH MAY CAUSE IT TO SEPARATE. CONSEQUENCE OF DEFECT: IF REAR SUSPENSION ATTACHMENTS SHOULD SEPARATE FROM THE UNDERBODY DURING VEHICLE USE, THE AXLE COULD SHIFT DURING ACCELERATION OR BRAKING AND MAY ADVERSELY AFFECT THE STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT.

Remedy: REINFORCE SUSPECT WELD LOCATIONS AND MODIFY TO PREVENT WELD FAILURE.

Reported: 1986-09-02 (September 2, 1986) · Model years: 1986

FUEL TANKS MAY HAVE BEEN SCORED OR PENETRATED WHEN FLOOR PAN MOUNTING HOLES FOR THE PARTITIONS WERE DRILLED. CONSEQUENCE OF DEFECT: FUEL LEAKAGE MAY OCCUR AND IN THE PRESENCE OF AN IGNITION SOURCE, THE POTENTIAL FOR A FIRE WOULD EXIST.

Remedy: REPLACE FUEL TANKS AS NECESSARY.

Reported: 1987-09-04 (September 4, 1987) · Model years: 1986, 1987

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Consequence: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

Remedy: INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.

Reported: 1988-06-06 (June 6, 1988) · Model years: 1986, 1987, 1988

VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE HAVE A TRAILER TAILLIGHT RELAY ASSEMBLY THAT CONTAINS WIRES OF SMALLER GAUGE THAN THE FUSE LINK WHICH PROTECTS THE CIRCUIT.

Consequence: SHOULD A SHORT CIRCUIT OCCUR IN THE WIRING WITHIN THERELAY OR IF WATER INTRUSION OCCURS THE SMALLER GAUGE WIRE IN THE RELAY WILLFUNCTION AS A FUSE LINK AND OVERHEAT. THE POSSIBILITY EXISTS FOR A FIRE IF THEWIRES ARE EXPOSED TO COMBUSTIBLE MATERIALS.

Remedy: INSTALLATION OF A RELAY WITH WIRES OF GAUGE ADEQUATE TO PROTECT THE CIRCUIT.

Reported: 1988-09-02 (September 2, 1988) · Model years: 1986

WIRING FOR THE POWER LUMBAR SEAT SYSTEM WAS ROUTED DIRECTLY BENEATH THE SEAT CUSHION SPRINGS AND MAY BE ABRADED BY THE SPRINGS.

Consequence: THIS COULD RESULT IN A SHORT CIRCUIT WHICH MAY CREATESUFFICIENT HEAT TO START A FIRE IN THE SEAT CUSHION PAD AND/OR TRIM COVER.

Remedy: INSTALL A FUSE WITHIN THE POWER LUMBAR ELECTRICAL CIRCUIT.

Reported: 1989-12-18 (December 18, 1989) · Model years: 1986, 1987

VANS WERE PRODUCED WITHOUT PLASTIC COVER DESIGNED TO COVER OUTBOARD SEAT BACK PIVOT HINGE ALLOWING WEBBING OF FRONT PASSENGER-SIDE SAFETY BELTS TO BECOME ABRADED OR CUT DUE TO CONTACT WITH EXPOSED HINGE.

Consequence: DAMAGE TO BELT WEBBING COULD WEAKEN BELTS TO POINT OFFAILURE INCREASING RISK OF INJURY IN AN ACCIDENT OR A SUDDEN STOP.

Remedy: INSTALL PLASTIC PIVOT COVER; REPLACE BELTS AS NECESSARY.

Reported: 1990-02-08 (February 8, 1990) · Model years: 1986

INSUFFICIENT INTERFERENCE FIT BETWEEN FUEL TANK FILLER PIPE AND GROMMET COULD RESULT IN AN INADEQUATE SEAL WHICH COULD ALLOW FUEL TO SEEP FROM THE JOINT.

Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, FUEL LEAKAGE COULD RESULT IN A FIRE.

Remedy: INSTALL A REVISED DESIGN GROMMET.

Reported: 1991-08-19 (August 19, 1991) · Model years: 1987, 1988

SOME LIFTGATE GAS CYLINDER-TO-BODY ATTACHMENT BALL STUDS MAY FRACTURE IN EITHER THE OPEN OR CLOSED POSITION.

Consequence: IF A BALL STUD FRACTURES, THE LIFTGATE WILL NOT REMAIN INTHE OPEN POSITION. BODILY INJURY COULD RESULT IF THE LIFTGATE DROPS WHILESOMEONE IS UNDER IT.

Remedy: REPLACE THE GAS CYLINDER-TO-BODY ATTACHMENT BALL STUDS.

Reported: 1996-04-25 (April 25, 1996) · Model years: 1988, 1989, 1990, 1991

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Consequence: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

Reported: 1998-08-11 (August 11, 1998) · Model years: 1988, 1989, 1990

VEHICLE DESCRIPTION: MINI VANS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA (10 SOUTHERN COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN), FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NEVADA (CLARK COUNTY), OKLAHOMA, SOUTH CAROLINA, AND TEXAS, AND IN THE U.S. TERRITORIES COVERED BY THE FEDERAL STATUTES. THE UPPER PORTION OF THE FUEL TANK CAN DEVELOP SMALL CRACKS DUE TO EXTENDED EXPOSURE TO VERY HIGH AMBIENT TEMPERATURES. FUEL VAPOR OR LEAKAGE COULD OCCUR AT THESE CRACKS.

Consequence: IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.

Remedy: DEALERS WILL REPLACE THE FUEL TANK, REGARDLESS OF MILEAGE, THROUGH MARCH 31, 2002. THIS COVERAGE WILL ONLY BE FOR STRUCTURAL CRACKS AT THE TOP OF THE TANK AND WILL NOT INCLUDE OTHER DAMAGE CAUSED BY AN ACCIDENT OR ROAD DEBRIS.

Reported: 1990-08-06 (August 6, 1990) · Model years: 1989, 1990

THE SECOND ROW RIGHT HAND SEAT ASSEMBLY HAS A TILT FORWARD FUNCTION. A LATCH RETAINS THE SEAT IN THE NORMAL RIDE POSTION, AND THIS LATCH MAY RELEASE UNDER SEVERE FRONTAL IMPACT CONDITIONS, ALLOWING THE SEAT TO PIVOT FORWARD.

Consequence: IN THE EVENT OF VEHICLE ACCIDENT, THE SEAT COULD PIVOTFORWARD, INCREASING THE RISK OF INJURY TO THE OCCUPANT.

Remedy: REPLACE SEAT PAWL ASSEMBLY WITH A REVISED DESIGN ASSEMBLY.

Reported: 1991-09-20 (September 20, 1991) · Model years: 1989, 1990, 1991

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.

Consequence: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.

Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Reported: 1991-11-04 (November 4, 1991) · Model years: 1989, 1990, 1991

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Consequence: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SURFACE, ANDINADVERTENT MOTION WHEN THE VEHICLE IS STARTED. ALL OF THESE CONDITIONS CANRESULT IN A VEHICLE ACCIDENT.

Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

Reported: 1989-12-11 (December 11, 1989) · Model years: 1990

INABILITY TO MAINTAIN PRESSURE IN THE SECONDARY SYSTEM OF THE MASTER CYLINDER (CONTROLS BRAKING OF REAR WHEELS) COULD INCREASE BRAKE PEDAL TRAVEL AND REDUCE BRAKE PERFORMANCE AT TEMPERATURES LESS THAN 40 DEGREES.

Consequence: THIS WOULD CAUSE REDUCED BRAKING EFFECTIVENESS ANDINCREASED STOPPING DISTANCE THAT COULD RESULT IN A CRASH OR COLLISION.

Remedy: INSTALL NEW DESIGN MASTER CYLINDER INCORPORATING A REDESIGNED SEAL.

Reported: 1997-11-13 (November 13, 1997) · Model years: 1992, 1993, 1994, 1995, 1996, 1997

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.

Consequence: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.

Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

Reported: 1999-02-09 (February 9, 1999) · Model years: 1992, 1993, 1994, 1995, 1996, 1997

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.

Consequence: THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.

Reported: 1999-04-28 (April 28, 1999) · Model years: 1992

VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). 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.

Consequence: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.

Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

Reported: 1999-02-09 (February 9, 1999) · Model years: 1994, 1995

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.

Consequence: HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.

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.

Reported: 1994-12-01 (December 1, 1994) · Model years: 1995

THE SPARE TIRE SUPPLIED WITH THE VEHICLE CAN CONTACT THE BRAKE LINES ON THE REAR AXLE IF IT IS MOUNTED IN THE UNDERBODY SPARE TIRE CARRIER. SUCH CONTACT COULD RESULT IN FRACTURE OF A REAR BRAKE LINE.

Consequence: THIS CAN RESULT IN REDUCED VEHICLE BRAKE CAPABILITY.

Remedy: DEALERS WILL INSTALL A LOWER PROFILE MINI-SPARE TIRE ON THE EXISTING MINI-SPARE WHEEL. THE NEW TIRE WILL ALLOW THE MINI-SPARE TO BE INSTALLED WITH APPROPRIATE CLEARANCES IN THE UNDERBODY SPARE TIRE CARRIER.

Reported: 1995-02-28 (February 28, 1995) · Model years: 1995

THE CERTIFICATION LABEL ON THESE VEHICLES HAVE INCORRECT REAR TIRE SIZES LISTED. P215/70R14SL SHOULD BE P215/75R14SL. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: THE INCORRECTLY SIZED REAR TIRE WOULD NOT HAVE SUFFICIENT LOAD CAPACITY FOR THE VEHICLE'S SPECIFIED GROSS AXLE WEIGHT RATING, INCREASING THE POTENTIAL FOR PREMATURE TIRE FAILURE.

Remedy: OWNERS WILL BE MAILED A SUPPLEMENTARY LABEL CONTAINING THE CORRECT REAR TIRE INFORMATION AND INSTRUCTIONS FOR INSTALLING THE LABEL ON THEIR VEHICLES. IF OWNERS PREFER, THEIR DEALER CAN INSTALL THE LABEL FOR THEM.

Reported: 1996-04-22 (April 22, 1996) · Model years: 1996

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."

Consequence: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.

Reported: 1996-08-29 (August 29, 1996) · Model years: 1996

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."

Consequence: INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .

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.

Reported: 2000-12-26 (December 26, 2000) · Model years: 1997

VEHICLE DESCRIPTION: MINIVANS EQUIPPED WITH 3.0L ENGINES. AN ACCELERATOR CABLE WAS KINKED DURING INSTALLATION, CAUSING THE CORE WIRES TO EVENTUALLY FRAY.

Consequence: THIS COULD INCREASE THE FRICTION IN THE CABLE, CAUSING THE THROTTLE TO BE SLOW TO RETURN TO IDLE. THIS CONDITION COULD RESULT IN A STUCK THROTTLE.

Remedy: DEALERS WILL INSTALL A NEW ACCELERATOR CABLE.