Defect
THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.
Consequence
THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.
Remedy
DEALERS WILL REPLACE THE IGNITION SWITCH.
1991 Ford Aerostar Recalls
Recalls on record Updated July 2026
The 1991 Ford Aerostar has 3 NHTSA recall campaigns affecting an estimated 8,696,842 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 282 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
Recall campaigns
Defect
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
Consequence
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.
Defect
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Consequence
VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
Remedy
REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
Complaints by component
ELECTRICAL SYSTEM:IGNITION:SWITCH
26fires
POWER TRAIN:AUTOMATIC TRANSMISSION
2crashes1fires
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
6crashes1fires2injuries
VEHICLE SPEED CONTROL
9crashes12injuries
ELECTRICAL SYSTEM:IGNITION
10fires
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
11fires
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
1crashes
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
EQUIPMENT:APPLIANCE:AIR CONDITIONER
1fires
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
6fires
Total complaints282
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“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 front brake rotors warped, causing the vehicle to shimmy. Dealership repaired the problem twice, but the consumer was still having the same problems. *ak”
“Transmission fluid entering coolant”
“Brakes overheat on a curvey road”
“Brakes overheat on a curvey road”
“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”
“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”
“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”
Defect investigations
Investigation EA99002 Opened 1999-01-07 · closed 2000-11-14
TRANSFER CASES AND REAR DRIVE SHAFT
There is no summary currently available
Investigation RQ97015 Opened 1997-10-29 · closed 1999-04-01
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
Sources & methodology
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Ford Aerostar as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.