1991 Ford AEROSTAR: complaints, problems and recalls
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.
Examples from the source records
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 10069585 · 2004-01-15 (January 15, 2004)
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
Owner-reported narrative. Look up ODI 10069585 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 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 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 10151871 · 2006-02-21 (February 21, 2006)
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM
Owner-reported narrative. Look up ODI 10151871 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 ↗
Recall history
3 distinct campaigns affect this selection. Announcement dates below are different from vehicle model years. A campaign may cover multiple years.
91V164000 · Seat Belts:Front:Anchorage
Reported: 1991-09-20 (September 20, 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.
NHTSA campaign record ↗91V189000 · Power Train:Automatic Transmission
Reported: 1991-11-04 (November 4, 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.
NHTSA campaign record ↗96V071000 · Electrical System:Ignition
Reported: 1996-04-25 (April 25, 1996)
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.
NHTSA campaign record ↗