Problems owners report
Complaints filed with NHTSA about the 1991 Ford Aerostar, by the system named in each complaint. One complaint can name several.
- Electrical system67
- Power train49
- Service brakes, hydraulic31
- Vehicle speed control23
- Equipment14
- Engine and engine cooling13
- Structure9
- Steering7
- Visibility6
- Latches/locks/linkages6
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 25 injuries and 1 deaths reported
Compared with other years
NHTSA ODI complaints by model year
New York safety inspections
At its first New York inspection the 1991 Ford Aerostar failed the safety check 3.51% of the time — 211% more often than the average 1991 passenger car (1.13%). Median odometer at inspection: 58,839 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls in Canada
5 Transport Canada recalls for the 1991 Ford Aerostar.
| 2001193 16 Jul 2001 | Other Certain vehicles, from Ontario to Newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicl… |
| 1995212 29 Nov 1995 | Electrical A SHORT CIRCUIT COULD DEVELOP IN THE IGNITION SWITCH THAT COULD LEAD TO OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN OF THE VEHICLE. THIS CONDIT… |
| 1992077 30 Jun 1992 | Lights And Instruments NOTE: ALSO INCLUDES SOME MEDIUM AND HEAVY TRUCKS. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 108 - LIGHTING. DAYTIME RUNNING LIGHT MODULE MAY MALFUNCTION … |
| 1992011 5 Feb 1992 | Emissions NOTE: TEMPO/TOPAZ WITH 2.3 LITRE ENGINE AND AEROSTAR WITH 3.0 LITRE ENGINE. THESE VEHICLES SO NOT COMPLY WITH C.M.V.S.S. 1103 - EXHAUST EMISSIONS. DEFECTIVE … |
| 1991149 6 Nov 1991 | Powertrain THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHI… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 1991 Ford Aerostar: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 635982 | SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT |
| 627752 | SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT |
| 623988 | INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC |
| 623944 | SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC |
| 622665 | ON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA AFTER AN ENGINE OIL PAN GASKET REPAIR HAS BEEN PERFORMED. *TT |
| 616522 | SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT |
| 613340 | EXPERIENCING A RAPPING OR CLANGING NOISE WHEN THE STEERING WHEEL IS TURNED RAPIDLY OR WHEN TURNING ON A BUMPY ROAD SURFACE. *TT |
| 613023 | THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS. *TT |
| 612203 | INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS |
| 6091931 | SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT |
| 6090087 | INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT |
| 6090051 | SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT |
| 6089681 | SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT |
| 608921 | SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT |
| 608431 | INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT |
| 606460 | EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP. *TT |
| 606420 | FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT |
| 605573 | SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED. *TT |
| 604059 | FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC |
| 603724 | MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK |
| 603717 | CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES. *YC |
| 601341 | EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT |
| 601312 | INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT |
| 601290 | INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC |
| 601269 | ANNOUNCING THE FORD OEM AIR CONDITIONING RETROFIT KIT AVAILABILITY. *YC |
NHTSA manufacturer communications (public domain)
NHTSA investigations
TRANSFER CASES AND REAR DRIVE SHAFT
PARKING PAWL
NHTSA Office of Defects Investigation