1996 Ford AEROSTAR: complaints, problems and recalls

ON 9/17/02 THE RIGHT FRONT ALLOY WHEEL CRACKED WHILE ON VACATION. WE WERE UNABLE TO TRAVEL IN IT. IT WAS EXPENSIVE AND DIFFICULT TO REPLACE. ON 2/1/03 (ALSO OUT OF TOWN) THE LEFT BACK ALLOY WHEEL CRACKED. WE ARE SEARCHING FOR A REPLAEMENT. OUR MECHANIC TOLD US THIS SHOULD NOT HAPPEN AND MUST BE A MANUFACTURING DEFECT. THERE ARE SEVERAL SIMILAIR COMPLAITS PLEASE EVALUATE AS IT COULD CAUSE A SEVERE ACCIDENT.

Owner-reported narrative. 124,500 miles reported. Look up ODI 10005362 at NHTSA ↗

WHILE DRIVING, THE TIRE EXPERIENCED TREAD SEPARATION. *AK *JB

Owner-reported narrative. 81,908 miles reported. Look up ODI 10031229 at NHTSA ↗

I NOTICED A "PINHOLE" ON MY VIPER GT TIRES, CONTACTED THE DEALER WHERE I PURCHASED THEM, THEY TOLD ME THAT THEY WERE NOT ON A RECALL LIST BUT WOULD REPLACE THEM FOR A "DIFFERENCE" COST. I RESEARCHED THE INTERNET AND DISCOVERED THAT 1-2 YEARS EARLIER COOPER (THE MANUFACTURER) GAD A RECALL ON A SIMILAR ISSUE. THE DOT NUMBER OF THE TIRES THAT HAD ON MY VAN WERE AS FOLLOWS: 30 HY UDN2802 - THIS TIRE HAD NO NOTICABLE PINHIOLE 30 HY UDN2401 - PINHOLE WITH VISIBLE WIRE THREADS VISIBLE 30 HY UDN2402 - PINHOLE WITH VISIBLE WIRE THREADS VISIBLE 30 HY…

Owner-reported narrative. 247,502 miles reported. Look up ODI 10033205 at NHTSA ↗

ONE OF SEVEN SPOKES ON LEFT FRONT ALLOY WHEEL/RIM IS CRACKED ALL THE WAY THROUGH. RIGHT REAR WHEEL/RIM IS STARTING TO CRACK (SHOWING ON TOP SURFACE). LOCAL FORD DEALER SAID THERE ARE NO RECALLS ON THIS ITEM. ONE LOCAL USED AUTO PARTS DISTRIBUTER SAID HE WAS NOT ALLOWED TO SELL THIS TYPE OF RIM BECAUSE OF POTENTIAL LIABILITY SUITS. ANOTHER USED PARTS DISTRIBUTER SAID HE GETS SEVERAL REQUEST A MONTH FOR THE SAME RIM. BASED ON THE NUMBER OF COMPLAINTS, FORD SHOULD RECALL THE RIMS BEFORE FAILURES/FATALITIES. *JB

Owner-reported narrative. Look up ODI 10039044 at NHTSA ↗

MY 1996 FORD AEROSTAR HAS 14X6 ALUMINUM ALLOW WHEEL RIMS. THE RIMS HAVE 7 TRIANGULAR SLOTS AND 7 WIDE/FLAT "SPOKES". ONE OF THESE RIMS IS CRACKING. THE CRACK IS PROGRESSING FROM ONE SPOKE TO ANOTHER. I HAVE STOPPED DRIVING THE VEHICLE ALL TOGETHER. AFTER ALMOST A MONTH OF SEARCHING FOR A USED REPLACEMENT RIM I HAVE FOUND OUT THAT I AM NOT THE ONLY ONE WITH THIS PROBLEM. I SUSPECTED THAT THIS MAY BE THE CASE WHEN I COULD NOT FIND ANY ON-LINE COMPANY THAT HAD THESE IN STOCK (USED OR NEW). TODAY I SPOKE WITH A WOMAN AT ACKERWHEELS.COM AND…

Owner-reported narrative. Look up ODI 10039066 at NHTSA ↗

THE CONSUMER RECEIVED A RECALL LETTER CONCERNING IGNITION SWITCH FAILURE ON 03/99. ON 10/21/03 CONSUMER STOPPED, PARKED VEHICLE, TOOK KEY OUT OF THE IGNITION, AND IGNITION CYLINDER CAME OUT. *AK

Owner-reported narrative. 81,300 miles reported. Look up ODI 10044646 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 ↗

WHILE DRIVING 70 MPH, THE REAR DRIVER SIDE TIRE TREAD SEPARATED. THE CONSUMER MANAGED TO PULL OVER TO CHANGE TIRE. THE DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. PLEASE PROVIDE MORE INFORMATION. SIZE#21570R14 DOT#HYHY4FA229. *NM

Owner-reported narrative. 99,500 miles reported. Look up ODI 10075653 at NHTSA ↗

Reported: 1996-04-22 (April 22, 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)

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: 1997-11-13 (November 13, 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)

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.