1990 FORD AEROSTAR Recalls, Complaints & Safety

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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.

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.

140,000 vehicles affected

SERVICE BRAKES, AIR:DISC:ROTOR

EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.

Remedy: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.

23,500 vehicles affected

ELECTRICAL SYSTEM:IGNITION

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

7,900,000 vehicles affected

POWER TRAIN:AUTOMATIC TRANSMISSION

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

Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

792,000 vehicles affected

SEAT BELTS:FRONT:ANCHORAGE

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

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

4,842 vehicles affected

SEATS:FRONT ASSEMBLY:RECLINER

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.

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

14,300 vehicles affected

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

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.

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

30,000 vehicles affected

1990 FORD AEROSTAR. CONSUMER STATES SUDDEN ACCELERATION NEARLY 20 YEARS AGO, THAT CAUSED OVER $1,000 IN DAMAGE. TGW THE CONSUMER STATED THE ACCIDENT HAPPENED WHEN THE VEHICLE WAS IDLING. *JB

Crash

1990 FORD AEROSTAR HAD CRACK IN FUEL TANK CAUSING CONSUMER TO REPLACE THE TANK. ***NO ANSWER REQUIRED*** *TS THE CONSUMER RECEIVED A RECALL LETTER IN DEC 1998 REGARDING THE GAS TANK, HOWEVER AT THE TIME HE WAS NOT EXPERIENCING PROBLEMS WITH THE GAS TANK. THE CONSUMER IS NOW REQUESTING REIMBURSEMENT FOR THE GAS TANK THAT HE HAD TO REPLACE. *JB

MY 1990 FORD AEROSTAR WAS LEAKING GASOLINE. THE FUMES WOULD OVERCOME YOU WHILE INSIDE THE VEHICLE. AFTER THE VAN SAT FOR A SHORT TIME GAS WOULD BE ALL OVER THE GROUND FROM THE LEAK. I PAID A FORD DEALER TO REPLACE THE TANK NOT KNOWING THERE WAS A RECALL. THE SAFETY OF MY FAMILY WAS IMPORTANT ENOUGH THAT I PAID THIS MONEY OUT OF MY POCKET. NOW FORD IS TELLING ME THAT MY VIN DOES NOT QUALIFY FOR THE RECALL. SO I AM NOT EVEN ELIGIBLE FOR A REIMBURSEMENT. PLEASE HELP. THANK YOU CARING FOR THE SAFETY OF ALL DRIVERS. *NM THE ASSIGNED IDENTIFICATION NUMBER FOR THIS RECALL CAMPAIGN 98V-190000 FORD RECALL NO. 98M03. *TT THE CONSUMER REQUESTED REIMBURSEMENT FOR THE CRACKED GAS TANK. FORD WILL NOT REFUND THE MONEY AND WILL NOT HELP. *SC

BRAKING SYSTEM -- MASTER CYLINDER

CONSUMER REQUESTING INFORMATION ON WHETHER OR NOT THERE WERE ANY RECALLS FOR VAN. *MR THE RECALLS ARE AS FOLLOWED: #96V071000, 98V190000, 91V189000, 91V164000, 90V144000, 98E010000, 98E010000 AND A RECALL ON THE TIRE TEMPORARY SPARE. *SC

TRANSMISSION WAS PLACED IN PARK AND VEHICLE ROLLED AWAY. THERE WAS NO NOTICES OF SUCH A RECALL OR ANY OTHER RECALLS, FOR THIS VEHICLE. 1990 FORD AEROSTAR. *JB

Crash

UPON STARTING THE VEHICLE, IT ACCELERATED AT A HIGH SPEED AND CRASHED INTO A BUILDING. THE DRIVER'S FOOT WAS ON THE BRAKE PEDAL WHEN SUDDEN ACCELERATION OCCURRED. THE VEHICLE WAS TOTALED. THE INSURANCE COMPANY INDICATED THAT THE INCIDENT WAS INCONCLUSIVE. THERE WAS A TRANSMISSION RECALL 91V189000, BUT THIS VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO VIN. *AK *SC *JB

Crash 3 injured

THE VEHICLE IS EXPERIENCING THE FAILURES DESCRIBED IN THE MASTER CYLINDER PISTONS RECALL 89V223000. IN ADDITION, THE ABS LIGHT COMES ON. ALSO, THE VEHICLE IS EXPERIENCING THE FAILURE DESCRIBED IN THE IGNITION SWITCH RECALL 96V071000 BUT THIS VEHICLE NOT INCLUDED IN RECALL DUE TO VIN. *AK

I JUST GOT MY TRANSMISSION FIXED BUT THE PROBLEM WAS I DIDN'T KNOW THAT THE FORD AEROSTAR HAS BEEN RECALLED... UNTIL NOW I HAVE THE SAME PROBLEM SOMETIMES NO SHIFTING, REVERSE ALWAYS HAVE A PROBLEM AND LATE SHIFTING (FORWARD).. I'M JUST WONDERING IF MY VEHICLE HAS ALREADY BEEN FIXED? CAN FORD DEALER FIX MY VAN WITHOUT ANY COST?

THE REAR ANTI LOCK BRAKES HAVE MALFUNCTIONED, CAUSING THE BRAKES TO LOCK. AS A RESULT THE STEERING LOCK AND THE VEHICLE LOST CONTROL. NO REPORT OF AIRBAG DEPLOYMENT. PLEASE PROVIDE ADDITIONAL INFORMATION. *NLM

Crash

VEHICLE TRANSMISSION FAILURE. *AK

NHTSARECALL 98-V-190-000 CONCERNING UPPER PORTION OF FUEL TANK THAT CAN DEVELOP SMALL CRACKS DUE TO EXTENDED EXPOSURE TO VERY HIGH AMBIENT TEMPERATURES. FUEL VAPOR OR LEAKAGE COULD OCCUR AT THESE CRACKS. CONSUMER HADTHE RECALL LETTER, BUT MANUFACTURER DIDN'T HONOR IT. PLEASE PROVIDE FURTHER INFORMATION.TS. *AK

CONSUMER STATES THE SAME PROBLEM AS RECALL #98V190000 FUEL TANK CRACKS. DEALER WILL NOT REPAIR BECAUSE VIN IS NOT INCLUDED. TS

NHTSA RECALL CAMPAIGN 98V190000 FUEL TANK; THE VAN WAS TAKEN IN AS A SERVICE CAMPAIGN BY FORD FOR THE FUEL TANK BACK IN 1999. AFTER INSPECTING THE FUEL TANK, THE DEALER TOLD HER THE TANK WAS FINE AND DIDN'T REPLACE IT. NOW IN 2002, THE FUEL TANK HAS DEVELOPED SEVERAL CRACKS WHICH THE FORD DEALERSHIP WILL NO LONGER HONOR THE SERVICE CAMPAIGN DUE TO AN "EXPIRATION DATE". PLEASE DESCRIBE DETAILS

WHILE DRIVING, THE LEFT FRONT AND LEFT REAR TIRES BLEWOUT, THERE WAS SOME DAMAGE TO THE VEHICLE, FUT TUR SE, P215/70R14, DOT NUMBER VDHYNMA396. *SLC

FUEL IS LEAKING FROM THE FILLER NECK WHEN REFUELING. DEALER CONTACTED. *AK THE CONSUMER STATES THAT THE FUEL RUNS OUT OF THE TOP OF THE FUEL TANK. *SCC

WHILE DRIVING AND WITHOUT WARNING THERE WAS A STRONG BURNING RUBBER SMELL DUE TO A FIRE IN ALTERNATOR SYSTEM. THIS WAS THE SECOND AEROSTAR STAR VEHICLE THAT HAD THIS PROBLEM.*AK

Fire

LEFT REAR TIRE BLEW OUT CAUSING THE VEHICLE TO SKID AND STRIKE THE GUARDRAIL.(OHIO TRAFFIC CRASH REPORT) *YH

1 injured

I PURCHASED MY VAN FROM MONARCH FORD IN EXETER MARCH OF 1996, BEFORE BUYING THE VAN I ASKED THEM TO PLEASE GIVE ME THE FORMER OWNERS PHONE NUMBER SO THAT I COULD CONTACT THEM INREGARDS TO ANY MAJOR PROBLEMS THEY HAD BEFORE SELLING IT BACK TO FORD. MONARCH FORD REFUSED AND I GUESS THAT SHOULD HAVE BEEN A WARNING TO ME, I ALSO ASKED IF THEY HAD REPAINTED THE VAN BECAUSE THE FORD AND AEROSTAR EMBLEMS WERE NOT ON THE BACK OF THE VAN. THEY SAID ABSOTULY NOT THAT IT WAS EVERYTHING THE SAME. IT WAS ONLY 10 MONTHS AFTER I PURCHASED MY VAN THAT I NOTICED A GAS SMELL AND HAD IT CHECK WITH MONARCH IN EXETER. THEY ASSURED ME THEY COULD NOT FIND THE SOURCE OF THE LEAK BUT THAT THEY COULD SMELL THE GAS. I HAVE SINCE HAD IT TO MANY OTHER STATIONS TO HAVE IT CHECK AND I GET THEY SAME ANSWER. I HAVE DONE SOME INVESTIGATING MYSELF AND FOUND THAT FORD HAS A EXSISTING PROBLEM WITH THEIR FUEL TANKS AND LEAKS. I FEEL THIS IS WHAT HAS HAPPEN IN MY CASE. I FEEL I HAVE A LEAK IN MY GAS TANK AND THAT IT NEEDS TO BE REPLACED. I FEEL THIS IS THE MANUFACTORS REPONSEABLITY AND THAT IT WHY I AM ASKING FOR YOUR HELP. THE GAS LEAK IS GETTING WORSE AND THE SMELL IS REALLY BAD. I NEED THIS VAN FIXED IT IS A HAZARD TO DRIVE. EVERYWHERE I TAKE IT THEY TELL ME THEY CAN SMELL IT AND THAT I SHOULD NOT DRIVE IT BUT THAT THEY CAN NOT FIND THE PROBLEM AND HAVE ALSO BEEN TOLD IT IS A FACTORY PROBLEM? CAN YOU TELL ME WHAT TO DO AND HOW I CAN GET THIS RESOLVED AS SOON AS POSSIBLE. I KNOW FORD HAS THIS PROBLEM I JUST DO NOT KNOW HOW IS THE BEST WAY TO GET IT FIXED. I WOULD APPREICATE ANY HELP YOU CAN GIVE ME SO THAT I CAN GET MY VAN SAFE FOR DRIVING AGAIN. PLEASE CAN YOU HELP ME. SINCERELY [XXX]. *AK PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

VEHICLE WAS PARKED. DRIVER TURNED IGNITION AND VEHICLE WAS IDLING WHEN IT STARTED TO REV, SUDDENLY TRANSMISSION JUMPED INTO REVERSE AND HIT A BUILDING.*AK

Crash

VEHICLE WAS PARKED. DRIVER TURNED IGNITION AND VEHICLE WAS IDLING WHEN IT STARTED TO REV, SUDDENLY TRANSMISSION JUMPED INTO REVERSE AND HIT A BUILDING.*AK

Crash

ELECTRICAL SYSTEM SHUTDOWN WITHOUT PRIOR WARNING. THERE IS A SIGN BURNING PLASTIC. RECALL NUMBER 96G07100. DEALERSHIP IS AWARE OF PROBLEM.*AK

MASTER CYLINDER LOSES PRESSURE AND BRAKE PEDAL GOES TO THE FLOOR, STOPS VEHICLE VERY LITTLE. CONSUMER MAY TRY IT NEXT TIME AND BRAKES WILL WORK FINE. THIS PROBLEM IS INTERMITTENT. CONSUMER CONTACTED FORD ABOUT RECALL ON BRAKES. FORD STATED THAT THERE WERE NO RECALL ON BRAKES. FORD FILE#9005975796. *AK *YH

DOOR LATCH ON DRIVER'S SIDE DOOR HAS BROKEN, CAUSING DOOR TO FLY OPEN WHILE DRIVING.*AK

VEHICLE HAS BEEN EXPERIENCING SAME PROBLEMS AS STATED IN RECALL 98V190000. UPPER PORTION OF FUEL TANK DEVELOPED CRACKS. DEALER HAS ADVISED OF DEFECT, BUT SAID THAT THIS VEHICLE WAS NOT PART OF RECALL. *AK

HEAT SHIELD BOLTS BROKE, HAVING PROBLEMS FIND TO REPAIR. *AK

HAD TWO BLOWOUTS WITHIN A MONTH ALMOST RESULTING IN CRASH (TIRESIZE: 205-75-14)( DOT NUMBER: TIRE SIZE: 205-75-14 )

ALL FOUR TIRES HAVE A CRACK ALL THE WAY AROUND THE SIDEWALLS AT TREAD LINE, IN SOME AREAS CRACKS TURN INTO TREAD (DOT NUMBER: 25741-2 ?? TIRESIZE: 215/60R15)

NO SUMMARY

LEAK WITHOUT APPARENT PUNCTURE. "PLUG" REPAIRED 2X. "TEAR" CONTINUES TO RUN. *AK( DOT NUMBER: HYHB4FA468 TIRE SIZE: P215/75R14 )

PLASTIC SNAP RETAINER BUSHING HOLDING THE CLUTCH PUSH ROD NO LONGER HOLDS PUSH ROD.*AK PUSH ROD FELL OFF OF THE STUD MAKING THE CLUTCH INOPERABLE. THE CLUTCH DISCONNECTING IN TRAFFIC MAKES THE VEHICLE HARD TO CONTEROL. *YH

O-RING FAILURES WERE REPORTED ON ONE OF YOUR OWN BULLETINS ITEM # SB014781. *AK

VEHICLE FIRE RELATED TO RECALL COMPONENT FAILURE (96V-071), PRIOR TO RECALL NOTIFICATION AND REPAIR. YH

Fire

WHEN STARTING CAR IT WON'T START, VEHICLE HAS POWER, BUT WON'T TURN OVER. WHEN SHIFTING INTO DRIVE THEN BACK INTO PARK, VEHICLE WILL START. CONSUMER FELT SHIFT LEVER WAS NOT LOCKING PROPERLY AND CAR MAY ROLL. *AK

WHILE TRAVELING STEERING WHEEL WOULD SHAKE AND PULL. DEALER HAS BEEN CONTACTED.PLEASE PROVIDE FURTHER INFORMATION. *AK

DOOR LATCH ON THE SLIDING DOOR WAS NOT FUNCTIONING, AND DOOR WON'T SHUT. DEALER INDICATED THAT BUMPER TO BUMPER WARRANTY HAD EXPIRED, AND THERE WAS NO RECALL. *AK

THERE IS A RECALL ON THE 1992 FORD AREOSTAR FOR ALL WHEEL DRIVE VANS FOR THE SAME FAILURE. RECALL 91V181000/AUTOMATIC TRANSMISSION. *AK

FUEL TANK HAS DEVELOPED CRACKS, CAUSING A FUEL TO LEAK .DLR HAS REPLACED FUEL TANK PRIOR TO RECALL 98V190000 BEING ISSUED. DEALER/MANUFACTURER STATED THAT VEHICLE VIN# IS NOT INCLUDED IN RECALL. *AK

VEHICLE STARTED ON FIRE WHILE MY WIFE WAS SHOPPING IN A TOY STORE. STRANGE ELECTRICAL PROBLEMS WERE REPORTED TO TOWNE FORD ORCHARD PARK NY 3 DAYS PRIOR. THEY SAID PROBLEMS WERE NOT RELATED TO THE IGNITION SWITCH RECALL

Fire

WHILE DRIVING 25MPH THE VEHICLE ACCELERATED SUDDENLY, RESULTING IN A COLLISION THAT CAUSED MINOR INJURIES. MANUFACTURER WILL BE NOTIFIED. *AK

Crash 2 injured

WHILE DRIVING 25MPH THE VEHICLE ACCELERATED SUDDENLY, CAUSING A COLLISION WHICH RESULTED IN MINOR INJURIES. MANUFACTURER WILL BE NOTIFIED. *AK

Crash 2 injured

CONSUMER INSERTED THE KEY INTO IGNITION AND SMOKE STARTED COMING FROM THE SWITCH. CONSUMER TURNED IGNITION OFF, AND NO FIRE WAS STARTED. DEALER HAS NOT SEEN VEHICLE. *AK

DRIVER'S SIDE SEAT BELT LATCHING MECHANISM FAILS TO WORK PROPERLY. ALSO, WHENEVER THE BRAKES ARE APPLIED & DRIVER LEANS FORWARD A BIT, THE BELT BUCKLE WOULD BECOME UNLATCHED, BY ITSELF. DRIVER HAS BUCKLE PART BY BENEDIX. HAVE BEEN TO DEALER. *AK

VEHICLE EXPERIENCED POSSIBLE RECALL COMPONENT FAILURE PRIOR TO NOTICE WHICH CAUSED VEHICLE FIRE (96V-071). MJS

Fire

PARKED FOR 12 HOURS PRIOR TO FIRE AT 3:50 AM.

Fire