1994 Ford Aerostar
Recalls, most-reported problems, crash-test ratings, fuel economy and what a 1994 Ford Aerostar is worth — from official NHTSA and EPA data. 2 on record.
1994 Ford Aerostar at a glance
Included: that car's specs and build sheet, model-year recall campaigns and a fair price.
1994 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: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.
Fix: DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.
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.
1994 Ford Aerostar common problems
The most-reported problem areas across all 303 owner complaints filed with NHTSA — and what to check before you buy.
1994 Ford Aerostar safety ratings
Source: NHTSA 5-Star Safety Ratings (NCAP), tested as the 1994 Ford Aerostar. Ratings can differ by body style and drivetrain.
1994 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 1994 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 1994 Ford Aerostar — ranges cover the 6 body / drivetrain versions on record. Source: Transport Canada vehicle specifications via NHTSA.
Canadian recalls 4
Transport Canada recall campaigns for the 1994 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
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 1999Electrical
On certain vehicles, a short circuit could cause heat damage, including melting or charring of the wire harness for the fuel pump and sender assembly and associated wire harnesses. In some cases the short circuit could have the potential for a vehicle fire. Correction: A fused jumper harness will be installed in the fuel pump ground circuit at the fuel pump inertia shut-off swi…
Transport Canada #1999031 · 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.