The 1990 Ford Aerostar has 5 recalls, the most serious being a brake master cylinder that loses pressure in cold weather, causing the pedal to sink toward the floor and significantly extending stopping distances.
Recalls 1 and 2 describe the same underlying defect: when temperatures drop below about 4 degrees Celsius (40 degrees Fahrenheit), the master cylinder cannot hold pressure in the circuit that controls the rear brakes, leaving the driver with reduced braking force and no advance warning before stopping distance grows. There is also a fuel system concern affecting vehicles registered in certain warm-weather states in the southern US: the fuel tank assembly can develop a leak, and if an ignition source is nearby, that leaked fuel can catch fire. On the occupant safety side, the second-row right-hand seat has a tilt-forward function held in place by a latch that can release in a severe frontal crash, allowing the seat to pitch forward and increase the risk of injury to whoever is sitting in it. Finally, vehicles registered in eastern Canada from Ontario to Newfoundland may have a corroded spare tire winch cable that can snap while driving, dropping the spare tire onto the road and creating a hazard for other vehicles.
At a glance
What can fail
The spare tire winch cable can corrode and break. If it fails while you're driving, the spare tire may drop onto the road.
What the fix does
Inspect the cable for corrosion or broken wires. If found, take your vehicle to a dealer to replace the winch assembly.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The upper part of the fuel tank can crack from prolonged exposure to very high heat, potentially causing fuel vapor or leakage.
What the fix does
The fuel tank will be replaced at no cost to you, covering structural cracks at the tank's top.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The second row right seat has a latch that may release during a severe frontal crash, causing the seat to tilt forward unexpectedly.
What the fix does
Replace the seat pawl assembly with a revised design that prevents unwanted release.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
In cold weather below 4°C, the brake master cylinder loses pressure in its secondary system, causing the brake pedal to travel farther and brake performance to decrease, which can increase stopping distance.
What the fix does
The master cylinder will be replaced with a new design that includes a redesigned seal to maintain pressure in cold conditions.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The master cylinder's secondary system may lose pressure in cold weather below 40°F, causing the brake pedal to travel further and reducing braking power to the rear wheels.
What the fix does
Install a new master cylinder with a redesigned seal that maintains pressure in the secondary braking system.
Summarized — see the official notice for exact wording, dates, and contacts.
