Looking at these recalls, they group into two distinct issues: an ignition switch electrical fault (Recalls 1 and 4) and an AWD drivetrain/transfer case structural failure (Recalls 2, 3, 5, and 6).
The 1992 Ford Aerostar has 6 recalls, all rated at the same severity level, covering two serious fire risks: a short circuit in the ignition switch and, on all-wheel drive models, a transmission and transfer case assembly that can fail and spray flammable fluid onto hot exhaust components.
The ignition switch carries excess electrical load through its accessory circuit, which can create a short and overheat the wiring, raising the risk of a fire even with the vehicle simply switched on. On AWD models, sustained highway driving above roughly 80 mph can cause the transmission and transfer case to fail structurally. When that happens, the assembly can expel fluid, and if that fluid reaches the exhaust system, it can ignite. The same failure can also separate the driveshaft from the vehicle, causing an abrupt and unpredictable loss of control. Prior repair attempts did not fully resolve the drivetrain issue for all affected vehicles, which is why multiple filings cover the same underlying problem.
