I had my starter replaced breaks and relay and it still having problems with the electrical system I cannot even turn on my headlights
The worst 1991 Ford Aerostar problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Electrical67
- Transmission49
- Brakes34
- Acceleration23
- Engine13
- Body9
- Steering7
- Locks6
- Visibility6
- Suspension5
- Fuel system4
- Lights3
- Seats3
- Tires3
- Seat belts2
Specific symptoms reported on the 1991 Ford Aerostar
Fire or smoke 33Sudden acceleration 10ABS 7Brake failure 7Transmission failure 5
Recalls 3
Electrical system: ignition
- What is wrong
- The ignition switch could experience an internal short circuit.
- Risk
- This condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.
- Remedy
- Dealers will replace the ignition switch.
Recall number 96V071000 · Recall details
Power train: automatic transmission
- What is wrong
- When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
- Risk
- Driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. All of these conditions canresult in a vehicle accident.
- Remedy
- Repair the transmission with a new park pawl.
Recall number 91V189000 · Recall details
Seat belts: front: anchorage
- What is wrong
- Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
- Risk
- Vehicles would not comply with fmvss 210.
- Remedy
- Replace noncomplying sofa bar with bar that meets requirements.
Recall number 91V164000 · Recall details
See all 3 recalls for the 1991 Ford Aerostar
Defect investigations
Transfer cases and rear drive shaft
There is no summary currently available
EA99002
Parking pawl
When the automatic shift lever is placed in the park position, the parking pawl does not always engage the park gear.this can lead to the vehicle jumping out of gear unintentionally and cause the vehicle to start rolling inadvertently
RQ97015
Technical service bulletins for the 1991 Ford Aerostar 48
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Some vehicles equipped with an automatic transmission and a 4.0L ohv engine may exhibit a noise /...
- Some vehicles equipped with the 4.0L ohv engine may exhibit an engine noise which may be perceived by the...
- Some vehicles may exhibit heater core leaks
- Information regarding transmission fluid usage charts
- On some vehicles, engine oil may continue to leak from the engine oil pan gasket area after an engine oil...
- Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the...
- Information regarding the new transmission cooler flusher- service tip
- Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses
- Information on identifying non-approved / alternate refrigerants which could cause safety, and performance...
- Service tip information on revised oil pan gasket replacement procedure
1991 Ford Aerostar fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 3.0L 6‑cyl | RWD | 15-17 | 21-22 | 17-19 |
| 4.0L 6‑cyl | RWD | 15 | 20 | 16-17 |
| 4.0L 6‑cyl | 4WD | 14 | 19 | 16 |
What 1991 Ford Aerostar owners say
Most recent owner complaints, unedited.
Consumer requesting recall information on 1991 aerostar recall. *ts
I owned a 1991 ford aerostar which burst into flames and was destroyed. I have been bounced around trying to get satisfactions but since there was an ongoing class action law suit have not received any compensation. The consumers wife noticed smoke coming from the steering column. The consumer pulled over, ran to call the fire department, but by the time he returned the vehicle was fully engulfed in flames. Updated 04/14/10.
The front brake rotors warped, causing the vehicle to shimmy. Dealership repaired the problem twice, but the consumer was still having the same problems.
While driving 65 MPH another motorist yelled at the consumer that the van was on fire. The fire appeared to be coming form the middle to the rear. Consumer pulled over, and noticed transmission fluid on the underside of the van. Consumer shut the engine off, and fire went out. A technician examined the van and stated that the transfer case needed to be replaced. The federal safety agency recall campaign 99v094000 was issued.
Transmission fluid entering coolant
1) replaced both head gaskets and bolts! 2) replaced extension housing gasket 3) replaced both valve cover gaskets, oil pan gasket, oil filter adapter o-rings
Brakes overheat on a curvey road
Passenger side sliding door will no longer open. Vehicle has not been examined by dealer. Nlm
Consumer states that while driving down highway the rear brakes locked and caused a fire which melted the rear tires. Consumer was travelling approx 65mph when the vehicle began to slow down and smoke began coming from the rear of vehicle.*jb.
Compare the 1991 Ford Aerostar
Other model years
Questions about the 1991 Ford Aerostar
Is the 1991 Ford Aerostar reliable?
Owners have filed 223 complaints about the 1991 Ford Aerostar, 1.4 times a typical Aerostar model year.
What is the most common problem with the 1991 Ford Aerostar?
Electrical system, with 67 complaints. Next is transmission (49).
How many recalls does the 1991 Ford Aerostar have?
3 recalls, covering electrical system, power train and seat belts.
Was there a recall on the 1991 Ford Aerostar electrical?
Yes, 1 recall: 96V071000. Check your VIN to see if your car still needs the free repair.
What year does the Ford Aerostar have the most electrical problems?
The Ford Aerostar model years with the most electrical complaints are 1993 (99 complaints), 1994 (69 complaints) and 1991 (67 complaints).
What gas mileage does the 1991 Ford Aerostar get?
Official estimates for the 1991 Ford Aerostar range from 16 to 19 mpg combined. The most efficient version (3.0L 6-cyl, RWD) gets 15-17 city and 21-22 highway.
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