Problems owners report
Complaints filed with NHTSA about the 1994 Ford Aerostar, by the system named in each complaint. One complaint can name several.
- Electrical system69
- Air bags44
- Power train42
- Service brakes, hydraulic23
- Engine and engine cooling22
- Steering20
- Fuel system, gasoline19
- Structure16
- Vehicle speed control12
- Seat belts12
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 33 injuries and 4 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 3 1994 Aerostar vehicles were involved in crashes on US public roads in which someone died; 2 people died inside them, and 3 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 1994 Ford Aerostar failed the safety check 1.18% of the time — 11% less often than the average 1994 passenger car (1.33%). Median odometer at inspection: 111,016 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls in Canada
4 Transport Canada recalls for the 1994 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… |
| 1999031 2 Mar 1999 | Electrical On certain vehicles, a short circuit could cause heat damage, including melting or charring of the wire harness for the fuel pump and sender assembly and associ… |
| 1999032 2 Mar 1999 | Electrical On certain vehicles, a short circuit could occur at the A2 accessory terminal in the ignition switch of these vehicles when the switch is in the "on" position c… |
| 1997207 20 Nov 1997 | Powertrain On certain Aerostar AWD vehicles, extended operation at speeds of over 130 kph may result in structural failure of the transmission/transfer case assembly. This… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
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.
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.
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 1994 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 |
| 625715 | BRAKE SHIFT INTERLOCK.*JB |
| 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 |
| 616508 | SPECIAL FIELD ACTION REGARDING REVISED WARANTY INFORMATION. *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 |
| 6090082 | INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT. *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 |
| 607372 | INFORMATION REGARDING TRANSFER CASE REAR HOUSING AND DRIVESHAFT REPLACEMENT. *TT |
| 606508 | CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK. *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 |
| 605562 | SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT. *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 |
NHTSA manufacturer communications (public domain)
NHTSA investigations
LUGGAGE COMPARTMENT DOOR DROPS ABRUPTLY
TRANSFER CASES AND REAR DRIVE SHAFT
TRANSFER CASES AND REAR DRIVESHAFT
FUEL SENDER ASSEMBLY FIRES
FUEL SENDER ASSEMBLY FIRES
NHTSA Office of Defects Investigation