1991 FORD AEROSTAR
4 recalls, 282 complaints - 48 TSBs
98E010000 Apr 8, 1998
SERVICE BRAKES, AIR:DISC:ROTOR
Defect Description
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.
Consequence
LOSS OF BRAKING CAN RESULT.
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.
96V071000 Apr 25, 1996
ELECTRICAL SYSTEM:IGNITION
Defect Description
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.
91V189000 Nov 4, 1991
POWER TRAIN:AUTOMATIC TRANSMISSION
Defect Description
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 VEH... Read more
Remedy
REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
91V164000 Sep 20, 1991
SEAT BELTS:FRONT:ANCHORAGE
Defect Description
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.
Complaint Statistics
282 total complaints
28 crashes 78 fires 31 injuries 1 deaths
Top Reported Components
| Component | Complaints |
|---|---|
| ELECTRICAL SYSTEM:IGNITION:SWITCH | 32 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 21 |
| VEHICLE SPEED CONTROL | 18 |
| POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH | 18 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP | 12 |
| ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD | 12 |
| ELECTRICAL SYSTEM:IGNITION | 12 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER | 11 |
| EQUIPMENT:APPLIANCE:AIR CONDITIONER | 9 |
| ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 8 |
ELECTRICAL SYSTEM
Jun 11, 2017
Incident date: May 9, 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
UNKNOWN OR OTHER
Feb 23, 2006
Incident date: Jan 1, 1901
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM
ELECTRICAL SYSTEM:IGNITION:SWITCH
May 16, 2005
Incident date: Aug 27, 1996
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 PUL... Read more
Fire
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
Aug 6, 2004
Incident date: Jan 8, 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
POWER TRAIN:AUTOMATIC TRANSMISSION
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 ... Read more
Fire
UNKNOWN OR OTHER
Apr 22, 2004
Incident date: Oct 15, 2003
TRANSMISSION FLUID ENTERING COOLANT
ENGINE AND ENGINE COOLING
Apr 22, 2004
Incident date: Nov 15, 2002
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
FUEL SYSTEM, GASOLINE
Apr 22, 2004
Incident date: Aug 15, 2003
BRAKES OVERHEAT ON A CURVEY ROAD
UNKNOWN OR OTHER
Apr 22, 2004
Incident date: Nov 15, 2002
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
SERVICE BRAKES, HYDRAULIC
Apr 22, 2004
Incident date: Aug 15, 2003
BRAKES OVERHEAT ON A CURVEY ROAD
POWER TRAIN
Apr 22, 2004
Incident date: Nov 15, 2002
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
STRUCTURE:BODY:DOOR
Oct 2, 2002
Incident date: Sep 20, 2002
PASSENGER SIDE SLIDING DOOR WILL NO LONGER OPEN. VEHICLE HAS NOT BEEN EXAMINED BY DEALER. NLM
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM
Jul 25, 2002
Incident date: Jul 23, 2002
CONSUMER STATES THAT WHILE DRIVING DOWN HIGHWAY THE REAR BRAKES LOCKED AND CAUSED A FIRE WHICH MELTED THE REAR TIRES. CONSUMER WAS TRAVELLING APPROX 65MPH WHEN THE VEHICLE BEGAN TO SLOW DOWN AND SMOKE BEGAN COMING FROM THE REAR OF VEHICLE.*JB.
Fire
EQUIPMENT:APPLIANCE:AIR CONDITIONER
Jul 1, 2002
Incident date: May 6, 2002
I WENT TO FIRESTONE IN ST. JOE, MO AND HAD MY AIR CONDITIONING RECHARGED AFTER 9 YEARS OF DRIVING MY VAN. THEY TOLD ME THAT I NEEDED TO REPLACE A HOSE ON THE FRONT OF THE VECHICAL AND THAT THEY NEEDED TO THEN ADD FREON TO THE SYSTEM. THAT WAS IN JULY 19, 2001. IT DIDN'T SEEM AS COLD AS IT HAD BEFO... Read more
VEHICLE SPEED CONTROL
Jun 11, 2002
Incident date: Jun 8, 2002
AS SOON AS CONSUMER SHIFTED TO DRIVE, VEHICLE ACCELERATED ON ITS OWN, WITH TIRES SPINNING. CONSUMER APPLIED BRAKES, THEN PARK BRAKE, AND SHIFTED TO NEUTRAL. CONSUMER ACCIDENTLY SHIFTED TO REVERSE AND HEARD A LOUD CLUNKING SOUND, VEHICLE CAME TO A STOP.*AK *JB
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
Jun 3, 2002
Incident date: May 1, 2002
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE. *AK
Crash
1 injured
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
Jun 3, 2002
Incident date: May 1, 2002
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE. *AK
Crash
1 injured
EXTERIOR LIGHTING:HEADLIGHTS:SWITCH
Jan 9, 2002
Incident date: Dec 22, 2001
I HAVE BEEN DRIVING AT NIGHT ON SEVERAL DIFFERENT OCCASIONS AND HAD THE HEADLIGHTS SUDDENLY GO OUT ON ME. THE SWITCH FOR THE LIGHTS SEEMS TO BE WARM AT THESE TIMES. THE HEATER SEEMS TO CAUSE THE SWITCH TO HEAT UP AND WHEN IT GETS HOT THE LIGHTS GO OFF. IT MAY CAUSE AN ACCIDENT ONE OF THESE TIMES IF ... Read more
POWER TRAIN:AUTOMATIC TRANSMISSION
Dec 7, 2001
Incident date: Nov 1, 1998
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSI... Read more
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
Dec 7, 2001
Incident date: Nov 1, 1998
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSI... Read more
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
Nov 21, 2001
WHILE TRAVELING AT ANY SPEED OR STOPPING AT LIGHT VEHICLE WOULD STALL WITHOUT ANY INDICATION. PLEASE PROVODE FURTHER INFORMATION. *AK
STRUCTURE:BODY:TAILGATE:HINGE AND ATTACHMENTS
Oct 16, 2001
Incident date: Aug 1, 2001
THE REAR LIFT SPRING ON THE REAR LIFTGATE BROKE AT THE UP POSISTION WHILE UNLOADING,CAUSING THE DOOR TO COME SLAMING DOWN ON MY BACK. *AK
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
Jul 9, 2001
Incident date: Jun 1, 2001
FOUR WHEEL DRIVE/TRANSFER CASE BLEW OUT AND CAUGHT ON FIRE. *AK
Fire
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
Jul 2, 2001
Incident date: Apr 7, 2001
WHILE DRIVING THE BRAKES FAILED RESULTING IN VEHICLE COLLISION WITH THREE INJURIES, UPON EXPECTION OF THE BRAKE PEDAL TRAVEL AND RESERVOIR (OSHP UNITS 977), NO PRESSURE ON THE PEDAL AND NO FLUID IN THE RESERVOIR (OHIO TRAFFIC CRASH REPORT) *MJS
3 injured
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
Jun 28, 2001
Incident date: Jun 21, 2001
THIS VEHICLE WAS DRIVEN FOR 20 MINUTES WHEN A STRONG ODOR OF PLASTIC BURNING WAS SMELLED. THIS VEHICLE WAS PARKED WHEN WHITE SMOKE WAS NOTICED COMING OUT FROM UNDER THE HOOD. A FEW SECONDS PASSED WHEN THE VEHICLE CAUGHT FIRE AND WAS TOTALLY INVOLVED. THIS VEHICLE WAS TOTALED. *AK
Fire
VEHICLE SPEED CONTROL
May 31, 2001
WHILE MAKEING A STOP WITH FOOT DEPRESSING BRAKE PEDAL VEHICLE STARTED IDLING HIGH. PLEASE PROVIDE FURTHER INFORMATION.*AK
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
May 17, 2001
Incident date: May 14, 2001
NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK
Fire
EXTERIOR LIGHTING:BRAKE LIGHTS
Apr 23, 2001
Incident date: Apr 10, 2001
MY WIFE HAS TOLD ME THAT ON SEVERAL OCCASIONS SHE HAS REPLACED THE BRAKE LIGHT ON THE RIGHT REAR OF HER 1991 FORD AEROSTAR. I SAW A FORD AEROSTAR MINIVAN WITH A BURNED OUT BRAKE LIGHT ON MY WAY TO WORK TODAY. PLUS SOMEONE TOLD ME ABOUT AN EXACT SAME PROBLEM INVOLVING A FORD AEROSTAR MINIVAN. I HAVE ... Read more
VEHICLE SPEED CONTROL:ACCELERATOR PEDAL
Apr 23, 2001
Incident date: Apr 20, 2001
AS CONSUMER TRIED TO PULL FORWARD, ENGINE REVVED AND VEHICLE ACCELERATED. PEDAL WAS STUCK ALL THE WAY TO FLOOR, VEHICLE WAS STOPPED BY CONCRETE WALL AFTER ABOUT 40 FT. VEHICLE TOTALLED. *AK
Crash
LATCHES/LOCKS/LINKAGES:HATCHBACK/LIFTGATE:LOCK
Apr 5, 2001
Incident date: Jun 15, 2000
THE REAR HATCHBACK FREEZES (LOCKED) CLOSED AND I AM NOT ABLE TO OPEN FROM EITHER SIDE. WHICH COULD PROVE DANGEROUS IN A CRASH SITUATION. THIS IS MY SECOND AEROSTAR WITH THE SAME PROBLEM. THE USEFULNESS OF THE VIHICAL IS CUT BY MORE THAN 75%
TIRES:TREAD/BELT
Mar 22, 2001
Incident date: Mar 18, 2001
PE00 202; CONSUMER WAS TRAVELING 60MPH ON HIGHWAY AND HEARD A POPPING NOISE, WAS ABLE TO PULL VEHICLE OVER. HE NOTICED THAT RIGHT REAR TIRE TREAD SEPARATED AND AIR WAS STILL INSIDE OF TIRE. FIRESTONE TIRE #P23575R15. THERE WERE NO INJURIES.*AK TREAD SEPARATION CAUSED DAMAGE TO VEHICLE. *... Read more
POWER TRAIN:DRIVELINE:DRIVESHAFT
Mar 13, 2001
Incident date: Feb 1, 2001
NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK
SEAT BELTS:FRONT:ANCHORAGE
Mar 7, 2001
Incident date: Jan 23, 2001
CONSUMER HAD BOUGHT A VEHICLE WITHOUT SEAT BELTS. DEALER REFUSED TO INSTALL SEAT BELTS. CONSUMER NEEDS THEM FOR CHILDREN SAFETY.*AK *SLC
SEATS
Feb 14, 2001
Incident date: Jun 7, 1998
THIS SEAT HAS NOW FAILED AGAIN. ALMOST LOST CONTROL OF VEHICLE BOTH TIMES. *AK
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
Jan 17, 2001
Incident date: Dec 9, 2000
VEHICLE WAS TOTALED. NO SAFETY DEFECT MENTIONED IN SUMMARY. *AK
Fire
ENGINE AND ENGINE COOLING:ENGINE
Dec 13, 2000
Incident date: Dec 4, 2000
THE FLYWHEEL HAS BEEN REPLACED 5 TIMES. IT CONTINUES TO TEAR APART NEAR WHERE IT IS BOLTED ON. THIS IS AN ONGOING PROBLEM THAT WE CANNOT SOLVE. MY MECHANIC CANNOT DETERMINE WHY THIS CONTINUES TO HAPPEN. *AK
SUSPENSION
Nov 16, 2000
Incident date: Dec 15, 1999
ONGOING PROBLEM WITH SEVERE VIBRATION WHILE TRAVELING AT 50 MPH. VEHICLE BEEN IN DEALER SHOP ON SEVERAL OCCASIONS, BUT PROBLEM STILL OCCURS. PLEASE FEEL FREE TO PROVIDE ANY FURTHER DETAILS ON THIS MATTER. *AK
TIRES:TREAD/BELT
Oct 25, 2000
Incident date: May 1, 2000
BRIDGESTONE TURANZA TIRES P215 70 R14 EXPERIENCED TREAD SEPARATION, CAUSING DAMAGE TO VEHICLE. *SLC
ELECTRICAL SYSTEM:IGNITION
Oct 25, 2000
Incident date: Oct 11, 2000
NO SUMMARY( DOT NUMBER: )
Fire
ELECTRICAL SYSTEM:IGNITION
Oct 25, 2000
Incident date: Oct 11, 2000
NO SUMMARY( DOT NUMBER: )
Fire
ELECTRICAL SYSTEM:IGNITION
Oct 25, 2000
Incident date: Oct 11, 2000
NO SUMMARY( DOT NUMBER: )
Fire
ELECTRICAL SYSTEM:IGNITION
Oct 25, 2000
Incident date: Oct 11, 2000
NO SUMMARY( DOT NUMBER: )
Fire
TIRES:TREAD/BELT
Oct 24, 2000
Incident date: May 1, 2000
BRIDGESTONE TURANZA TIRES P215 70 R14 EXPERIENCED TREAD SEPARATION, CAUSING DAMAGE TO VEHICLE. *SLC
ELECTRICAL SYSTEM:IGNITION
Oct 12, 2000
Incident date: Oct 10, 2000
VEHICLE CAUGHT ON FIRE IN UNDER DASH. VEHICLE WAS TOTALED. DEALER COULD NOT DETERMINE THE CAUSE OF THE FIRE. *AK THE 1991 FORD AEROSTAR HAD A RECALL FOR THE IGNITION COLUMN (96V-071). THE DEALER CLAIMS TO HAVE FIXED IT BUT IT CAUGHT FIRE. *YH
Fire
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH
Oct 12, 2000
Incident date: Oct 10, 2000
VEHICLE CAUGHT ON FIRE IN UNDER DASH. VEHICLE WAS TOTALED. DEALER COULD NOT DETERMINE THE CAUSE OF THE FIRE. *AK THE 1991 FORD AEROSTAR HAD A RECALL FOR THE IGNITION COLUMN (96V-071). THE DEALER CLAIMS TO HAVE FIXED IT BUT IT CAUGHT FIRE. *YH
Fire
POWER TRAIN:AUTOMATIC TRANSMISSION
Sep 5, 2000
Incident date: Aug 27, 2000
A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP RE... Read more
EQUIPMENT:APPLIANCE:AIR CONDITIONER
Sep 5, 2000
Incident date: Aug 27, 2000
A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP RE... Read more
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM
Sep 5, 2000
Incident date: Aug 27, 2000
A/C WAS INOPERATIVE WHEN VEHICLE WAS PURCHASED FROM DEALER. DEALER REPAIRED A/C AS CONDITION OF PURCHASE. A/C FAILED AGAIN ABOUT A MONTH AFTER REPAIR AND HAS BEEN INOPERATIVE SINCE. REAR DIFFERENTIAL STARTED MAKING A LOW WHINING NOISE THAT BECAME A LOUD WHINING NOISE AFTER A COUPLE DAYS. ENDED UP RE... Read more
POWER TRAIN:AUTOMATIC TRANSMISSION
Aug 28, 2000
Incident date: Jul 9, 2000
CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD ... Read more
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
Aug 28, 2000
Incident date: Jul 9, 2000
CONSUMER WAS TRAVELING ABOUT 75MPH ON HIGHWAY WHEN DRIVESHAFT BENT, CAUSING THE FAILURE OF THE TRANSFER CASE AND TRANSMISSION. VEHICLE WAS VIBRATING AND THERE WAS TRANSMISSION FLUID LEAKING FROM UNDERNEATH VEHICLE. THERE WERE NO PRIOR WARNING. HE TOOK VEHICLE TO DEALERSHIP, AND MECHANIC TOLD ... Read more
Showing 50 of 282 complaints.
Technical Service Bulletins, 1991 FORD AEROSTAR
48 manufacturer communications from 48 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 103000 POWER TRAIN:AUTOMATIC TRANSMISSION | 6 |
| 061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 6 |
| 357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER | 3 |
| 062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS | 2 |
| 353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC. | 2 |
| 980000 UNKNOWN OR OTHER | 2 |
| 103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER | 2 |
| 114000 ELECTRICAL SYSTEM:WIRING | 2 |
02142
Jul 22, 2002
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
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
01197
Oct 1, 2001
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
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
01157
Aug 6, 2001
980000 UNKNOWN OR OTHER
INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC
01156
Aug 6, 2001
138600 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE
SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC
01124
Jun 25, 2001
061000 ENGINE AND ENGINE COOLING:ENGINE
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
002310
Nov 13, 2000
103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES
SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT
0015
Jan 10, 2000
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS
99222
Oct 18, 1999
114000 ELECTRICAL SYSTEM:WIRING
SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT
99196
Sep 20, 1999
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER
INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT
99183
Sep 6, 1999
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT
13118
Aug 1, 1999
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT
6896
Aug 1, 1999
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
SOME VEHICLES MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / CONNECTING ROD BEARING KNOCK. *TT
99152
Jul 26, 1999
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
INFORMATION ON THE NEW FLUSH AND FILL TOOL AVAILABLE THROUGH ROTUNDA. *TT
99129
Jun 14, 1999
353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
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
99816
May 3, 1999
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR. *TT
98246
Dec 7, 1998
110000 ELECTRICAL SYSTEM
FORD MOTOR COMPANY HAS RELEASED A NEW ELECTRICAL GREASE ( F8AZ - 19G208-AA ) TO REDUCE THE POSSIBILITY OF MOISTURE CORROSION AT THE TERMINALS. *YC
982310
Nov 23, 1998
063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
MASS AIR FLOW (MAF)- SENSOR CONTAMINATION- SERVICE TIP. *AK
98233
Nov 23, 1998
106000 POWER TRAIN:AXLE ASSEMBLY
CONCERNS WITH FRONT DRIVE AXLE FLUID MAY LEAK OUT OF THE VENT UNDER SOME DRIVING MODES ON SOME VEHICLES. *YC
9888
Apr 27, 1998
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART. *YC
9852
Apr 13, 1998
190000 TIRES
INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE. *YC
9873
Apr 13, 1998
353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
EXPERIENCING A WHINING / BUZZING NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO. *TT
9864
Mar 30, 1998
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
INFORMATION ON A BUZZING OR RATTLE NOISE FROM THE EXHAUST SYSTEM. *TT
985A12
Mar 18, 1998
354600 EQUIPMENT:MECHANICAL:WRECKER AND WHEEL LIFT DEVICES
RECOMMENDED GUIDELINES FOR TOWING BEHIND RECREATIONAL VEHICLES. *TT
985A52
Mar 18, 1998
034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
THIS BULLETIN CONTAINS SERVICE TIPS WHEN SERVICING ANY BRAKE RELATED ROUGHNESS / PULL CONCERNS. *TT
985A13
Mar 18, 1998
034500 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC
THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE. *YC
9848
Mar 2, 1998
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER
ANNOUNCING THE FORD OEM AIR CONDITIONING RETROFIT KIT AVAILABILITY. *YC
9832
Feb 16, 1998
162200 STRUCTURE:BODY:BUMPERS
FRONT AND REAR BUMPERS MADE OF XENOY PLASTIC HAVE HAD THE CONDUCTIVE PRIMER REMOVED FROM SERVICE PARTS. *YC
98112
Jan 19, 1998
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
SUBJECT REGARDING A NEW SERVICE CENTER SUPPORT THAT USES A THRUST BEARING (#3 AND #4) IN PLACE OF THRUST WASHERS HAS BEEN RELEASED. *TT
9768
Mar 17, 1997
980000 UNKNOWN OR OTHER
FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE. *JD
97511
Mar 3, 1997
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
FLUID- TRANSMISSION FLUID USAGE CHARTS. *JD
9747
Feb 17, 1997
160000 STRUCTURE
FRAME- RIVET REPLACEMENT WITH BOLTS- SERVICE TIPS. *JD
BC1019997230
Jan 23, 1997
062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS
4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPNIED WITH A THUMPING NOISE OR FEEL IN THE COOLANT HOSES WITH THE ENGINE AT NORMAL OPERATING TEMPERATURE. *JD
BC3485972301
Jan 23, 1997
062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS
4.0L EQUIPPED VEHICLES MAY EXPERIENCE TEMPERATURE GAUGE FLUCTUATION THAT MAY BE ACCOMPANIED WITH A THUMPING NOISE OR FEEL IN THE COOLANT HOSE WITH THE ENGINE AT NORMAL OPERATING TEMPERATURE. *JD
962612
Dec 16, 1996
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER
TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP. *TW
962617
Dec 16, 1996
034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
BRAKES - BRAKE SERVICE - SERVICE TIPS. *TW
96249
Nov 18, 1996
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER
TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP. *TW
96246
Nov 18, 1996
114000 ELECTRICAL SYSTEM:WIRING
WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS. *TW
96221
Oct 21, 1996
131000 VISIBILITY:WINDSHIELD
WINDSHIELD AND INTERIOR GLASS - FOG/FILM. *TW
96719
Mar 25, 1996
010000 STEERING
EXPERIENCING A RAPPING OR CLANGING NOISE WHEN THE STEERING WHEEL IS TURNED RAPIDLY OR WHEN TURNING ON A BUMPY ROAD SURFACE. *TT
95212
Oct 1, 1995
036000 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE INCOMPATIBLE WITH THE RUBBER MATERIAL USED IN THE DISC BRAKE SYSTEM. IF PETROLEUM-BASED GREASE IS USED TO LUBRICATE ANY PAR
BC1350950906
Sep 1, 1995
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
HIGH ALTITUDE TRANSMISSION AVAILABLE. *TW
BC1383950906
Sep 1, 1995
015200 STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS
VEHICLE MAY EXHIBIT A MOAN WHEN TURNING - TO CORRECT THIS CONDITION, REPLACE THE HIGH PRESSURE HOSE WITH A TUNED HOSE. *TW
951614
Aug 1, 1995
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER
AIR CONDITIONING-POOR PERFORMANCE EVEN THOUGH A/C SYSTEM IS FUNCTIONING PROPERLY SERVICE TIPS. *SD
951612
Aug 1, 1995
162300 STRUCTURE:BODY:DOOR
DOOR-REPLACEMENT SLIDING - SERVICE TIP. *SD
95161
Aug 1, 1995
162000 STRUCTURE:BODY
SHEET METAL-ROOF PANEL AND DRIP RAIL REPLACEMENT- SEAM SEALER APPLICATION PROCEDURE.*SD
95153
Jul 1, 1995
062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
TEMPERATURE GAUGE - FLUCTUATING AND /OR INACCURATE HIGH READINGS. *SD
95102
May 1, 1995
116000 ELECTRICAL SYSTEM:IGNITION
VEHICLES MAY HAVE A DISCONNECT OF THE IGNITION CONTROL MODULE (ICM) CONNECTOR OR MOISTURE BUILDUP WITHIN THE CONNECTOR. *TW
94249
Nov 1, 1994
133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
FRONT DOOR GLASS TIPPING AND BINDING DURING DOWNWARD TRAVEL. *TW
NHTSA Safety Investigations, FORD AEROSTAR
Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.
PE02076
Opened: Oct 10, 2002 , Closed: Mar 10, 2003
LUGGAGE COMPARTMENT DOOR DROPS ABRUPTLY
ODI HAS IDENTIFIED 30 INCIDENTS RESULTING IN MINOR TO MODERATE PERSONAL INJURIES THAT HAVE BEEN CAUSED BY ABRUPT DOOR DROPS OVER THE APPROXIMATELY EIGHT - TWELVE YEAR PERIOD OF PRODUCT USAGE AND EXPOSURE (1991-1995 TO 2003).MOST OF THE INJURY INCIDENTS APPEAR TO HAVE BEEN CAUSED BY A FRACTURE OF THE... Read more
PE99035
Opened: May 12, 1999 , Closed: Sep 23, 1999
FRONT BRAKE HOSE
ALLEGED THAT A FRONT BRAKE HOSE RUPTURES OR FAILS AT THE INTERFACE BETWEEN THE RUBBER HOSE AND THE BRASS FITTING
EA99002
Opened: Jan 7, 1999 , Closed: Nov 14, 2000
TRANSFER CASES AND REAR DRIVE SHAFT
There is no summary currently available
RQ98012
Opened: Jul 31, 1998 , Closed: Jan 7, 1999
TRANSFER CASES AND REAR DRIVESHAFT
There is no summary currently available
EA98016
Opened: Jul 14, 1998 , Closed: Feb 12, 1999
FUEL SENDER ASSEMBLY FIRES
There is no summary currently available
PE98010
Opened: Feb 13, 1998 , Closed: Jul 14, 1998
FUEL SENDER ASSEMBLY FIRES
OWNERS ALLEGE THAT FAILURE OF THE FUEL PUMP/SENDER CONNECTOR RESULTS IN SHORT CIRCUIT THAT HAS RESULTED IN VEHICLE FIRES.SYMPTOMS INCLUDE ERRATIC FUEL GAUGE OPERATION, , SMOKE FROM THE DASH ON THE DRIVER'S SIDE NEAR THE STEERING COLUMN (FUEL PUMP FUSIBLE LINK) AND PASSENGER SIDE (FUEL PUMP INERTIA C... Read more
RQ97015
Opened: Oct 29, 1997 , Closed: Apr 1, 1999
PARKING PAWL
WHEN THE AUTOMATIC SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARKING PAWL DOES NOT ALWAYS ENGAGE THE PARK GEAR.THIS CAN LEAD TO THE VEHICLE JUMPING OUT OF GEAR UNINTENTIONALLY AND CAUSE THE VEHICLE TO START ROLLING INADVERTENTLY
EA96030
Opened: Dec 20, 1996 , Closed: Aug 13, 1998
CRACKED FUEL TANKS
CRACKED FUEL TANKS ARE LEAKING FUEL
PE96050
Opened: Aug 6, 1996 , Closed: Dec 20, 1996
CRACKED FUEL TANKS
CRACKED FUEL TANKS ARE LEAKING FUEL
EA94025
Opened: Jul 19, 1994 , Closed: Sep 30, 1997
SEAT BELT BUCKLE FAILURE
There is no summary currently available
PE94021
Opened: Mar 4, 1994 , Closed: Jul 19, 1994
SEAT BELT BUCKLE FAILURE
There is no summary currently available
PE91127
Opened: Sep 16, 1991 , Closed: Nov 8, 1991
PARK PAWL BENDING
There is no summary currently available
EA91015
Opened: Feb 1, 1991 , Closed: Sep 20, 1991
LIFTGATE FAILURE
There is no summary currently available
PE91005
Opened: Oct 18, 1990 , Closed: Feb 1, 1991
LIFTGATE FAILURE
There is no summary currently available
EA90042
Opened: Aug 31, 1990 , Closed: Dec 31, 1991
THROTTLE STICKING
There is no summary currently available
PE90072
Opened: Apr 9, 1990 , Closed: Jun 19, 1990
LOWER CNTRL ARM FRACTURE
There is no summary currently available
EA89032
Opened: Aug 3, 1989 , Closed: Apr 5, 1990
SAFETY BELT FRAYING
SUMMARY:COMPLAINTS OF CUTTING AND FRAYING OF SEAT BELT ON SHARP METALEDGE ON THE FRONT PASSENGER SEAT.EDGE IS UNPROTECTED ON 86'S COVEREDON LATER MODELS.ALL COMPLAINTS ON 86'S AND 87'S (1 COMPLAINT ON 87MODEL).UPGRADE ON 1986 AND 1987 MODELS.===
EA89021
Opened: Mar 23, 1989 , Closed: May 4, 1990
WINDSHIELD WIPER MOTOR
===
PE89092
Opened: Feb 23, 1989 , Closed: Jul 20, 1989
POWER STEERING LOCKING
SUMMARY:THE COMPLAINTS ALLEGE THAT POWER STEERING WAS STIFF ORSTEERING LOCKED.FORD HAS ISSUED TWO SERVICE BULLETINS:ONE ON LEAKINGSEALS AND ONE ON COMPLAINTS OF STIFF STEERING.===
PE89021
Opened: Dec 9, 1988 , Closed: Aug 3, 1989
SEAT BELT CUTTING
There is no summary currently available
PE89010
Opened: Nov 1, 1988 , Closed: Mar 23, 1989
WINDSHIELD WIPER MOTOR
There is no summary currently available
EA88041
Opened: Sep 15, 1988 , Closed: May 11, 1990
FILLER PIPE SEAL
===
EA88033
Opened: May 11, 1988 , Closed: Jan 23, 1989
UNDER SEAT FIRES
There is no summary currently available
PE88048
Opened: Apr 19, 1988 , Closed: Sep 15, 1988
FUEL LEAKAGE
BRIEFING: I. WHAT IS THE DEFECT? II. SOURCE/ORIGIN OF THE DEFECT?III. DATA ANALYSIS. IV. FORD'S POSITION.V. DESIGN CHANGES? VI. RECOMMENDATIONS.===
EA88030
Opened: Apr 19, 1988 , Closed: Jul 13, 1988
ELECTRICAL FIRES
There is no summary currently available
EA88028
Opened: Mar 23, 1988 , Closed: Jul 31, 1989
DOOR FALLS OFF
There is no summary currently available
EA88027
Opened: Mar 4, 1988 , Closed: Sep 15, 1988
REAR BRAKE LOCKUP
There is no summary currently available
PE88026
Opened: Feb 9, 1988 , Closed: Apr 27, 1988
CRNKSHFT PULLEY BOLT FAILR
There is no summary currently available
PE88006
Opened: Nov 30, 1987 , Closed: Apr 19, 1988
FIRES
SUMMARY OF INFORMATION FROM MANUFACTURER:INFORMATION PROVIDED BY FORDDISCLOSED 8 OWNER AND FIELD REPORTS OF 10 FIRES IN THE LEFT D-PILLAR AREAOF THE SUBJECT VEHICLES.NO COLLISION ACCIDENTS WERE REPORTED, BUT EACHINCIDENT INVOLVED PROPERTY DAMAGE DUE TO FIRE.IN ADDITION, FORD'S RECORDSINCLUDE AT LEAS... Read more
PE87052
Opened: Sep 9, 1987 , Closed: Mar 4, 1988
REAR BRAKE LOCKUP
ANALYSIS:THE SIX REPORTS ALLEGE THAT WHILE ENGAGING IN NORMAL DRIVING ONDRY PAVEMENT, BRAKE PEDAL APPLICATION RESULTED IN THE LOSS OF DIRECTIONALSTABILITY AND CONTROL OF THE VEHICLE.FOUR INJURY ACCIDENTS HAVE RESULTED,WITH THREE OCCURRENCES OF VEHICLE ROLL-OVER.THERE HAVE BEEN NO TSB'S ORRECALLS ISS... Read more
EA87020
Opened: May 7, 1987 , Closed: Sep 24, 1987
ENGINE COMPARTMENT FIRES
ANALYSIS:A REVIEW OF FORD MOTOR COMPANY'S RESPONSES TO ODI INFORMATIONREQUESTS ISSUED UNDER PRELIMINARY EVALUATIONS PE 87-012, PE 87-017, ANDPE 87-020, INDICATED THAT THE FAILURE AND/OR MALFUNCTION OF THE SPRING-LOCKFUEL LINE COUPLINGS APPEARED TO BE THE MAJOR SOURCE OR CAUSE OF ENGINECOMPARTMENT FI... Read more
FORD AEROSTAR - All Years Overview
Complete safety history for the FORD AEROSTAR across all model years (1986, 1997).
68
Total Recalls
3,116
Total Complaints
31
Investigations
268
Reported Crashes
516
Reported Fires
19
Reported Deaths
FORD AEROSTAR - Year by Year
Compare recalls and complaints across model years. Click any year to see full details.