The 1986 Ford Aerostar has 7 NHTSA recall campaigns affecting an estimated 3,998,841 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 72 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
INSUFFICIENT INTERFERENCE FIT BETWEEN FUEL TANK FILLER PIPE AND GROMMET COULD RESULT IN AN INADEQUATE SEAL WHICH COULD ALLOW FUEL TO SEEP FROM THE JOINT.
IN THE PRESENCE OF AN IGNITION SOURCE, FUEL LEAKAGE COULD RESULT IN A FIRE.
INSTALL A REVISED DESIGN GROMMET.
VANS WERE PRODUCED WITHOUT PLASTIC COVER DESIGNED TO COVER OUTBOARD SEAT BACK PIVOT HINGE ALLOWING WEBBING OF FRONT PASSENGER-SIDE SAFETY BELTS TO BECOME ABRADED OR CUT DUE TO CONTACT WITH EXPOSED HINGE.
DAMAGE TO BELT WEBBING COULD WEAKEN BELTS TO POINT OFFAILURE INCREASING RISK OF INJURY IN AN ACCIDENT OR A SUDDEN STOP.
INSTALL PLASTIC PIVOT COVER; REPLACE BELTS AS NECESSARY.
WIRING FOR THE POWER LUMBAR SEAT SYSTEM WAS ROUTED DIRECTLY BENEATH THE SEAT CUSHION SPRINGS AND MAY BE ABRADED BY THE SPRINGS.
THIS COULD RESULT IN A SHORT CIRCUIT WHICH MAY CREATESUFFICIENT HEAT TO START A FIRE IN THE SEAT CUSHION PAD AND/OR TRIM COVER.
INSTALL A FUSE WITHIN THE POWER LUMBAR ELECTRICAL CIRCUIT.
VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE HAVE A TRAILER TAILLIGHT RELAY ASSEMBLY THAT CONTAINS WIRES OF SMALLER GAUGE THAN THE FUSE LINK WHICH PROTECTS THE CIRCUIT.
SHOULD A SHORT CIRCUIT OCCUR IN THE WIRING WITHIN THERELAY OR IF WATER INTRUSION OCCURS THE SMALLER GAUGE WIRE IN THE RELAY WILLFUNCTION AS A FUSE LINK AND OVERHEAT. THE POSSIBILITY EXISTS FOR A FIRE IF THEWIRES ARE EXPOSED TO COMBUSTIBLE MATERIALS.
INSTALLATION OF A RELAY WITH WIRES OF GAUGE ADEQUATE TO PROTECT THE CIRCUIT.
SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.
COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.
INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.
FUEL TANKS MAY HAVE BEEN SCORED OR PENETRATED WHEN FLOOR PAN MOUNTING HOLES FOR THE PARTITIONS WERE DRILLED. CONSEQUENCE OF DEFECT: FUEL LEAKAGE MAY OCCUR AND IN THE PRESENCE OF AN IGNITION SOURCE,…
REPLACE FUEL TANKS AS NECESSARY.
THERE MAY BE INADEQUATE WELDING IN SOME UNDERBODY STRUCTURAL AREAS, INCLUDING THOSE AT THE REAR SUSPENSION ATTACHMENTS, WHICH MAY CAUSE IT TO SEPARATE. CONSEQUENCE OF…
REINFORCE SUSPECT WELD LOCATIONS AND MODIFY TO PREVENT WELD FAILURE.
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“The grommet in the fuel tank is leaking. Fuel is escaping from the tank and may cause a fire. There is a constant escape of fuel moving or stationary. Therefore this system will not pass smog because when pressurized, it will not hold air. This is a california requirement. It is also most…”
“Transmission was rebuilt 3 years ago at ford dealer, then, in oct 2000 while driving 55 mph transmission went out again. *ak”
“Possible wiring harness in the engine failure resulting in fire. Nlm”
“Possible wiring harness in the engine failure resulting in fire. Nlm”
“Possible wiring harness in the engine failure resulting in fire. Nlm”
“Vehicle experienced engine fire, consumer believes this failure is related to past recalls. Nlm”
“The front of starter cracked upon starting the vehicle. *ak”
“Had filled vehicle with gasoline. Noticed that the tank had started to leak afterwards. Took vehicle to dealer & had it checked. The mechanic noticed the fuel was leaking from the top of the tank in & around the seam area.*ak”
ANALYSIS:A REVIEW OF FORD MOTOR COMPANY'S RESPONSES TO ODI INFORMATIONREQUESTS ISSUED UNDER PRELIMINARY EVALUATIONS PE 87-012, PE 87-017, ANDPE 87-020, INDICATED THAT THE FAILURE AND/OR MALFUNCTION OF THE SPRING-LOCKFUEL LINE COUPLINGS APPEARED TO BE THE MAJOR SOURCE OR CAUSE OF ENGINECOMPARTMENT FIRES IN THE SUBJECT…
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SUMMARY:COMPLAINTS OF CUTTING AND FRAYING OF SEAT BELT ON SHARP METALEDGE ON THE FRONT PASSENGER SEAT.EDGE IS UNPROTECTED ON 86'S COVEREDON LATER MODELS.ALL COMPLAINTS ON 86'S AND 87'S (1 COMPLAINT ON 87MODEL).UPGRADE ON 1986 AND 1987 MODELS.===
There is no summary currently available
There is no summary currently available
ANALYSIS:THE SIX REPORTS ALLEGE THAT WHILE ENGAGING IN NORMAL DRIVING ONDRY PAVEMENT, BRAKE PEDAL APPLICATION RESULTED IN THE LOSS OF DIRECTIONALSTABILITY AND CONTROL OF THE VEHICLE.FOUR INJURY ACCIDENTS HAVE RESULTED,WITH THREE OCCURRENCES OF VEHICLE ROLL-OVER.THERE HAVE BEEN NO TSB'S ORRECALLS ISSUED WITH RESPECT…
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BRIEFING: I. WHAT IS THE DEFECT? II. SOURCE/ORIGIN OF THE DEFECT?III. DATA ANALYSIS. IV. FORD'S POSITION.V. DESIGN CHANGES? VI. RECOMMENDATIONS.===
There is no summary currently available
There is no summary currently available
SUMMARY:THE COMPLAINTS ALLEGE THAT POWER STEERING WAS STIFF ORSTEERING LOCKED.FORD HAS ISSUED TWO SERVICE BULLETINS:ONE ON LEAKINGSEALS AND ONE ON COMPLAINTS OF STIFF STEERING.===
There is no summary currently available
There is no summary currently available
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Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1986 Ford Aerostar as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.