The 1992 Ford Aerostar has 3 NHTSA recall campaigns affecting an estimated 848,152 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 439 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
Recall campaigns
POWER TRAIN99V0940001999-04-2810,951 affected
Defect
VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT…
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.
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…
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.
POWER TRAIN97V2040001997-11-1375,000 affected
Defect
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. …
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.
Complaints by component
ELECTRICAL SYSTEM:IGNITION:SWITCH
34
12fires2injuries
POWER TRAIN:AUTOMATIC TRANSMISSION
34
1crashes1fires22injuries
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
21
1fires
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
19
4crashes1fires4injuries
AIR BAGS:FRONTAL
15
14crashes36injuries
ENGINE AND ENGINE COOLING:ENGINE
14
EQUIPMENT:APPLIANCE:AIR CONDITIONER
14
2fires
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS
13
3crashes1injuries
AIR BAGS
10
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
10
3fires
Total complaints439
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Seatbelt dont work. *tr”
“Tl*the contact owns a 1992 ford aerostar. Upon purchasing the vehicle, the contact stated that the muffler was rusted and cracked. The dealer stated that the vehicle was fine and the fumes would exit out of the rear of the vehicle. The fire department stated that the fumes were entering the…”
“Tl*the contact owns a 1992 ford aerostar. Upon purchasing the vehicle, the contact stated that the muffler was rusted and cracked. The dealer stated that the vehicle was fine and the fumes would exit out of the rear of the vehicle. The fire department stated that the fumes were entering the…”
“Tl*the contact owns a 1992 ford aerostar. Upon purchasing the vehicle, the contact stated that the muffler was rusted and cracked. The dealer stated that the vehicle was fine and the fumes would exit out of the rear of the vehicle. The fire department stated that the fumes were entering the…”
“Tl*the contact owns a 1992 ford aerostar. Upon purchasing the vehicle, the contact stated that the muffler was rusted and cracked. The dealer stated that the vehicle was fine and the fumes would exit out of the rear of the vehicle. The fire department stated that the fumes were entering the…”
“Tl*the contact owns a 1992 ford aerostar. The contact stated that the cruise controls shuts on and off without warning. Several years ago, he witnessed billows of smoke coming from the vehicle. The vehicle has not been inspected or repaired. The speed and powertrain were unknown. The current and…”
“Dt*: the contact stated that the vehicle's horizontal and vertical headlight adjusters fractured on 07/04/06. The vehicle was taken to the dealer on 07/05/06 who determined that there was no replacement part available to repair the problem. The tension spring that assists in the proper functioning…”
“Dt*: the contact stated when the vehicle was placed in drive, it failed to move forward. The vehicle currently only operates in reverse. The vehicle was seen by a local mechanic who determined the transmission needed to be replaced. The transmission had gone out previously and was replaced by a…”
Defect investigations
InvestigationEA99002 Opened 1999-01-07 · closed 2000-11-14
TRANSFER CASES AND REAR DRIVE SHAFT
There is no summary currently available
InvestigationPE02076 Opened 2002-10-10 · closed 2003-03-10
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 GAS FILLED LIFT…
InvestigationPE99035 Opened 1999-05-12 · closed 1999-09-23
FRONT BRAKE HOSE
ALLEGED THAT A FRONT BRAKE HOSE RUPTURES OR FAILS AT THE INTERFACE BETWEEN THE RUBBER HOSE AND THE BRASS FITTING
InvestigationRQ97015 Opened 1997-10-29 · closed 1999-04-01
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
InvestigationRQ98012 Opened 1998-07-31 · closed 1999-01-07
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1992 Ford Aerostar as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.