1991 Ford Aerostar
Recalls, most-reported problems, crash-test ratings, fuel economy and what a 1991 Ford Aerostar is worth — from official NHTSA and EPA data. 1 on record.
1991 Ford Aerostar at a glance
Included: that car's specs and build sheet, model-year recall campaigns and a fair price.
1991 Ford Aerostar recalls 4
EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
Fix: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Fix: DEALERS WILL REPLACE THE IGNITION SWITCH.
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Fix: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Fix: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
Source: U.S. NHTSA, checked 4 Nov 2026. A campaign covers the model year; to see whether a particular car still needs the repair, check its VIN on NHTSA.gov or ask a franchised dealer.
1991 Ford Aerostar common problems
The most-reported problem areas across all 260 owner complaints filed with NHTSA — and what to check before you buy.
1991 Ford Aerostar MPG & running costs
Source: U.S. EPA / DOE fueleconomy.gov. The EPA lists 8 versions of this model year; combined is shown as a range and the other figures are averages.
Estimated 5-year cost to own
A rough guide to what running a 1991 Ford Aerostar costs over five years and 75,000 miles.
How this is estimated: fuel is the U.S. EPA annual cost at 15,000 miles a year. There aren't enough comparable listings to estimate depreciation for this model, so it is left out. Not included: insurance, maintenance, repairs, taxes, registration and finance costs. Treat it as a comparison guide, not a quote.
Dimensions & weight
Manufacturer-reported figures for the 1991 Ford Aerostar — ranges cover the 7 body / drivetrain versions on record. Source: Transport Canada vehicle specifications via NHTSA.
Investigations & service bulletins
NHTSA defect investigations 2
TRANSFER CASES AND REAR DRIVE SHAFT Closed
NHTSA #EA99002 · Power Train · opened Jan 1999 · closed Nov 2000PARKING PAWL Closed
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
NHTSA #RQ97015 · Power Train · opened Oct 1997 · closed Apr 1999An investigation means NHTSA is examining a possible defect — it is not a recall, and many close without one.
Manufacturer service bulletins 48
Technical notes the manufacturer sent to dealers about known issues and fixes. Useful to mention to a mechanic — they are not recalls and repairs may not be covered. Showing the 10 most recent of 48.
SOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A NOISE / VIBRATION, NO DRIVE, UNUSUAL NOISE DURING CRANKING OR A NO CRANK CONDITION. *TT
Bulletin 02142 · Engine And Engine Cooling · Jul 2002SOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE PERCEIVED BY THE CUSTOMER AS A PISTON / ONNECTING ROD BEARING KNOCK. *TT
Bulletin 01197 · Engine And Engine Cooling · Oct 2001SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC
Bulletin 01156 · Visibility · Aug 2001INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC
Bulletin 01157 · Aug 2001ON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA AFTER AN ENGINE OIL PAN GASKET REPAIR HAS BEEN PERFORMED. *TT
Bulletin 01124 · Engine And Engine Cooling · Jun 2001SUBJECT REGARDING CONTAMINATION FROM PRIOR TRANSMISSION CONCERNS OR EXCESS WEAR MAY BE TRAPPED IN THE TRANSMISSION FLUID COOLING SYSTEM. *TT
Bulletin 002310 · Power Train · Nov 2000INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP. *MJS
Bulletin 0015 · Power Train · Jan 2000SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES. *TT
Bulletin 99222 · Electrical System · Oct 1999INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS. *TT
Bulletin 99196 · Equipment · Sep 1999SERVICE TIP INFORMATION ON REVISED OIL PAN GASKET REPLACEMENT PROCEDURE. *TT
Bulletin 99183 · Engine And Engine Cooling · Sep 1999Source: NHTSA Office of Defects Investigation, listed for the AEROSTAR. Model-year data, not specific to one car.
Canadian recalls 5
Transport Canada recall campaigns for the 1991 Ford Aerostar. Relevant if the car was first sold in, or imported from, Canada.
Other
Certain vehicles, from Ontario to Newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicle is being driven, the spare tire could drop down, potentially creating a roadway obstacle. Correction: Owners are to inspect the cable, and if corrosion or broken wire strands are present the vehicle is to be taken to a…
Transport Canada #2001193 · Jul 2001Electrical
A SHORT CIRCUIT COULD DEVELOP IN THE IGNITION SWITCH THAT COULD LEAD TO OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN OF THE VEHICLE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS IN USE OR UNATTENDED. CORRECTION: IGNITION SWITCH WILL BE REPLACED WITH A REVISED DESIGN SWITCH.
Transport Canada #1995212 · Nov 1995Lights And Instruments
NOTE: ALSO INCLUDES SOME MEDIUM AND HEAVY TRUCKS. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 108 - LIGHTING. DAYTIME RUNNING LIGHT MODULE MAY MALFUNCTION WHICH CAN RESULT IN DAYTIME RUNNING LIGHTS THAT DIM, FLICKER OR GO OFF OR IN SOME INSTANCES MAY REMAIN ON AFTER THE IGNITION IS TURNED OFF. CORRECTION: DAYTIME RUNNING LIGHT MODULE WILL BE REPLACED ON AFFECTED VEHICLES.
Transport Canada #1992077 · Jun 1992Emissions
NOTE: TEMPO/TOPAZ WITH 2.3 LITRE ENGINE AND AEROSTAR WITH 3.0 LITRE ENGINE. THESE VEHICLES SO NOT COMPLY WITH C.M.V.S.S. 1103 - EXHAUST EMISSIONS. DEFECTIVE THROTTLE POSITION SENSORS CAN WEAR OUT PREMATURELY CAUSING AN INTERRUPTION OF THE SENSOR SIGNAL AND ILLUMINATION OF THE MALFUNCTION INDICATOR LIGHT. CORRECTION: THROTTLE POSITION SENSOR WILL BE INSPECTED AND REPLACED IF NEC…
Transport Canada #1992011 · Feb 1992Powertrain
THE PARK MECHANISM OF THE A4LD AUTOMATIC TRANSMISSION MAY NOT ENGAGE WHEN THE SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. IF PARKED ON AN INCLINE, THE VEHICLE MAY ROLL AS IF IN NEUTRAL IF THE PARKING BRAKE IS NOT SET. THIS COULD RESULT IN A VEHICLE ACCIDENT OR PERSONAL INJURY. CORRECTION: OWNERS WILL BE NOTIFIED OF CONDITION AND ADVISED TO SET THE PARKING BRAKE EACH TIME T…
Transport Canada #1991149 · Nov 1991Source: Transport Canada Motor Vehicle Safety Recalls Database.
About the Ford Aerostar
The Ford Aerostar is a range of vans that was manufactured by Ford from the 1986 to the 1997 model years. The first minivan produced by Ford, the model line was marketed against the Chevrolet Astro/GMC Safari and the first two generations of the Chrysler minivans. Introduced shortly before the Ford Taurus, the Aerostar derived its name from its slope-nosed "one-box" exterior.
From Wikipedia, licensed CC BY-SA 4.0. Describes the model line in general, not this model year specifically.