1992 Ford Aerostar
Recalls, most-reported problems, crash-test ratings, fuel economy and what a 1992 Ford Aerostar is worth — from official NHTSA and EPA data. 6 on record.
1992 Ford Aerostar at a glance
Included: that car's specs and build sheet, model-year recall campaigns and a fair price.
1992 Ford Aerostar recalls 5
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN …
Fix: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT BUSHING DISPLACEMENT CAN RESULT IN STRUCTURAL FAILURE OF THE TRANSMISSION AND/OR TRANSFER CASE. FLUID EXPL…
Fix: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES WERE PRODUCED WITH A HIGHER THAN SPECIFIED ELECTRICAL LOAD THROUGH THE ACCESSORY POWER FEED CIRCUIT. THE POTENTIAL FOR CONTACT BETWEEN THE B2 (BATTERY), A2 (ACCESSORY), AND P1 (PROOF) CIRCUITS CAN OCCUR, CREATING A SHORT CIRCUIT, ALLOWING CURRENT TO FLOW THROUGH THE GROUND WIRE.
Fix: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.
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.
VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. THESE VEHICLES CAN DEVELOP POWERTRAIN BENDING RESONANCE OR TRANSFER CASE OUTPUT SHAFT BUSHING DISPLACEMENT. THE POWERTRAIN BENDING RESONANCE OR THE OUTPUT SHAFT BUSHING DISPLACEMENT CAN RESULT IN STRUCTURAL FAILURE OF THE TRANSMISSION AND/OR TRANSFER CASE. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Fix: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
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.
1992 Ford Aerostar common problems
The most-reported problem areas across all 367 owner complaints filed with NHTSA — and what to check before you buy.
1992 Ford Aerostar safety ratings
Source: NHTSA 5-Star Safety Ratings (NCAP), tested as the 1992 Ford Aerostar. Ratings can differ by body style and drivetrain.
1992 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 1992 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 1992 Ford Aerostar — ranges cover the 7 body / drivetrain versions on record. Source: Transport Canada vehicle specifications via NHTSA.
Investigations & service bulletins
NHTSA defect investigations 5
LUGGAGE COMPARTMENT DOOR DROPS ABRUPTLY Closed
ODI HAS IDENTIFIED 30 INCIDENTS RESULTING IN MINOR TO MODERATE PERSONAL INJURIES THAT HAVE BEEN CAUSED BY ABRUPT DOOR DROPS OVER THE APPROXIMATELY EIGHT - TWELVE YEAR PERIOD OF PRODUCT USAGE AND EXPOSURE (1991-1995 TO 2003). MOST OF THE INJURY INCIDENTS APPEAR TO HAVE BEEN CAUSED BY A FRACTURE OF THE GAS FILLED LIFT ASSIST CYLINDER MOUNTING STUD. STUD FRACTURES HAVE OCCURRED RANDOMLY OVER TIME AND DO NOT EXHIBIT ANY…
NHTSA #PE02076 · Structure · opened Oct 2002 · closed Mar 2003FRONT BRAKE HOSE Closed
ALLEGED THAT A FRONT BRAKE HOSE RUPTURES OR FAILS AT THE INTERFACE BETWEEN THE RUBBER HOSE AND THE BRASS FITTING
NHTSA #PE99035 · Service Brakes, Hydraulic · opened May 1999 · closed Sep 1999TRANSFER CASES AND REAR DRIVE SHAFT Closed
NHTSA #EA99002 · Power Train · opened Jan 1999 · closed Nov 2000TRANSFER CASES AND REAR DRIVESHAFT Closed
NHTSA #RQ98012 · Power Train · opened Jul 1998 · closed Jan 1999PARKING 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 62
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 62.
NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT
Bulletin 03148 · Power Train · Jul 2003LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ
Bulletin 02176 · Exterior Lighting · Sep 2002SOME 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 2001BRAKE SHIFT INTERLOCK.*JB
Bulletin 01181 · Power Train · Sep 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 2000Source: NHTSA Office of Defects Investigation, listed for the AEROSTAR. Model-year data, not specific to one car.
Canadian recalls 4
Transport Canada recall campaigns for the 1992 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 2001Powertrain
On certain all wheel drive vehicles, extended operation at speeds of over 130 KPH may result in structural failure of the transmission/transfer case assembly. This could result in fluid expulsion, driveshaft separation or loss of vehicle drive. Fluid leakage in the presence of an ignition source, could cause a vehicle fire and driveshaft separation may lead to loss of vehicle c…
Transport Canada #1999078 · May 1999Electrical
On certain vehicles, a short circuit could occur at the A2 accessory terminal in the ignition switch of these vehicles when the switch is in the "on" position causing overheating and the potential for a vehicle fire. Correction: A jumper harness with a relay will be installed which will re-route and activate all A2 accessories through the relay.
Transport Canada #1999032 · Mar 1999Powertrain
On certain Aerostar AWD vehicles, extended operation at speeds of over 130 kph may result in structural failure of the transmission/transfer case assembly. This could result in fluid expulsion, driveshaft separation or loss of vehicle drive. Fluid leakage in the presence of an ignition source could cause a vehicle fire and driveshaft separation may lead to loss of vehicle contr…
Transport Canada #1997207 · Nov 1997Source: 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.