The 1993 Ford Aerostar has 2 NHTSA recall campaigns affecting an estimated 837,201 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 541 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
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
48
14fires
EQUIPMENT:APPLIANCE:AIR CONDITIONER
24
AIR BAGS:FRONTAL
22
19crashes19injuries
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
21
1fires
VEHICLE SPEED CONTROL
19
3crashes
POWER TRAIN:AUTOMATIC TRANSMISSION
17
2crashes1fires2injuries
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
17
3crashes1injuries
AIR BAGS
15
4crashes4injuries
ELECTRICAL SYSTEM:IGNITION
13
4fires
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH
12
7fires
Total complaints541
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl* the contact owns a 1993 ford aerostar. While driving at approximately 80 mph, there was a vibration coming from the driver side and there was fluid leaking from the vehicle. The contact noticed that the transmission transfer case was fractured and fluid was leaking. The vehicle was towed to…”
“Backed into pine tree in driveway. Shattered plastic bumper cover. Can not replace bumper cover because ford says obsolete. Also no after market bumper can be found for this model. This bumper protects no one. *js ford won't even give me the ford part number. Its a cargo van. Other model covers…”
“Tl* the contact owns a 1993 ford aerostar. The contact stated that the key became lodged in the ignition. The vehicle was not taken to the dealer for a diagnostic testing. The manufacturer was notified of the failure. The vin was not available. The approximate failure mileage was 169,000.”
“Tl*the contact owns a 1993 ford aerostar. The contact stated that he noticed electrical problems. There was a clicking sound and he could feel a pulsation in the dashboard; there were also electrical shortages. He called the dealership about recall 99v029000 and was told that his vehicle was not…”
“Bought four tires: sigma shadow. 55,000 miles warranty. 215/75r14, 6k60, at tire kingdom located at: 8790 sw 24th st. Miami, fl. 33165. Telephone [REDACTED]. *tr on oct. 22, 2007 the rear right tire blewout. The tire had 7,194 miles. Tire kingdom gave me two tires which they installed in the…”
“Just got home and was parked in front of the house. About 30 min later someone was knocking on are door telling us the van was on fire. There was no keys left in the van. The fire burn the dash and the right side of the inside of the engine and the hood. The van is now total. *nm”
“Dt*: the contact stated upon changing both the fuel filter and the oil filter, the vehicle made a knocking noise while driving 20 mph. The vehicle was taken to a private repair shop who was unable to determine the cause of the problem.”
“Tl*the contact owns a 1993 ford aerostar. The contact stated that his vehicle was 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; therefore,…”
Defect investigations
InvestigationEA98016 Opened 1998-07-14 · closed 1999-02-12
FUEL SENDER ASSEMBLY FIRES
There is no summary currently available
InvestigationEA98016 Opened 1998-07-14 · closed 1999-02-12
FUEL SENDER ASSEMBLY FIRES
There is no summary currently available
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…
InvestigationPE98010 Opened 1998-02-13 · closed 1998-07-14
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 CUTOFF SWITCH),…
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 1993 Ford Aerostar as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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