Summary
The Ford Aerostar has 28 recalls spanning the 1986-1997 production run, with the most serious recent issue being a kinked accelerator cable on 1997 models with 3.0-liter engines where fraying wire strands can increase cable friction, causing the throttle to stick open and raising the risk of a crash.
The 1996 model year has a recall for incorrect mass airflow sensors that can cause the vehicle to exceed emissions standards. The 1995 model year has two related issues: an underbody spare tire carrier that lets the spare contact the rear brake lines, eventually fracturing a line and causing loss of rear braking, and a certification label listing the wrong rear tire size, which could lead to underloaded tires with insufficient capacity for the vehicle's weight.
The 1994 model has a wiring harness to the fuel pump and sender assembly that can develop a short circuit, generating enough heat to melt or char surrounding wiring and potentially start a fire. On 1992 models, ignition switch circuits can short and overheat, creating a fire risk. Also on 1992 all-wheel-drive examples, sustained highway speeds above roughly 80 mph can cause structural failure of the transmission and transfer case, leading to fluid expulsion that can ignite on the exhaust, driveshaft separation, or complete loss of drive power.
The 1990 model year has a master cylinder that loses pressure in the secondary circuit at temperatures below freezing, causing the brake pedal to travel further and stopping distances to increase without warning. A 1990 fuel tank filler pipe seal can also leak fuel in warm-climate states, and 1990 quad captain's chair models have a second-row right seat latch that can release in a frontal impact, letting the seat pivot forward into occupants.
Going back to the late 1980s, 1989 models with quad captain's chairs have the same second-row seat latch issue, and the 1989 automatic transmission park mechanism can fail to engage, allowing the vehicle to roll on a slope. The 1988 ignition switch can develop a short circuit that overheats the steering column and can cause a fire whether the vehicle is running or parked. On 1987 models, the rear liftgate gas cylinder attachment studs can fracture, causing the liftgate to drop unexpectedly on anyone standing beneath it.
The earliest production years carry several issues: 1986 models have a fuel tank filler pipe seal that can leak fuel near ignition sources, trailer tow package wiring that can overheat and catch fire, rear suspension attachment welds that can fail and allow the axle to shift under acceleration or braking, and front passenger seatbelt webbing that can fray against the seat back hinge and weaken over time.
