The 1986 Ford Aerostar has 4 recalls, with three posing a fire or structural risk: fuel can seep from a poorly sealed filler pipe joint, undersized wiring in the optional trailer tow package can overheat, and rear suspension welds may fail.
On the fire side, a leaking fuel tank filler pipe seal allows fuel to escape near the base of the filler neck when the tank is full or nearly full, and any nearby ignition source can cause that fuel to ignite. Vehicles equipped with the optional trailer tow package face a separate fire risk: the taillight relay wiring uses a smaller gauge wire than the fuse protecting the circuit, so a short or water intrusion can cause those wires to overheat and catch fire rather than the fuse blowing first. On the structural side, the rear suspension attachment points may have inadequate welds where the suspension connects to the underbody, and if those welds let go, the axle loses its normal range of motion during acceleration and braking, which can pull the vehicle off course and reduce steering control. The remaining recall covers the front passenger seatbelt, where the webbing can rub and cut against the outboard seat back pivot hinge over time, gradually weakening the belt so it may not hold as intended in a crash.
At a glance
What can fail
The seal between the fuel tank filler pipe opening and grommet may be inadequate, allowing fuel to seep from the joint when the tank is full or nearly full.
What the fix does
The grommet will be replaced with a revised design that provides a proper seal.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The front passenger seat belt webbing can become frayed or cut where it rubs against the seat back pivot hinge.
What the fix does
A plastic cover will be installed over the hinge to stop the rubbing. Seat belts will be inspected and replaced if damaged.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The taillight relay wires in the trailer tow package are undersized compared to the fuse protecting the circuit. A short circuit or water in the relay could cause these wires to overheat and potentially catch fire.
What the fix does
A fuse will be installed in the trailer tow relay power circuit to protect it from short circuits and overheating.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
Welds connecting rear suspension parts to the vehicle underbody may be inadequate, allowing these parts to separate during driving. This could limit axle movement and affect steering control.
What the fix does
No remedy description available.
Summarized — see the official notice for exact wording, dates, and contacts.
