The 1996 Ford Aerostar has 4 NHTSA recall campaigns affecting an estimated 1,045,471 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 124 complaints with NHTSA, most often about the wheels. Last updated July 5, 2026.
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…
Consequence
THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.
Remedy
DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.
POWER TRAIN97V2040001997-11-1375,000 affected
Defect
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. …
Consequence
THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Remedy
DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
EQUIPMENT96V1610001996-08-29134,770 affected
Defect
THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Consequence
INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .
Remedy
OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.
WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."
Consequence
THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.
Remedy
DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.
Complaints by component
WHEELS
15
WHEELS:RIM
8
LATCHES/LOCKS/LINKAGES:DOORS:LATCH
6
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
6
1crashes
AIR BAGS:FRONTAL
5
5crashes4injuries
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
5
3crashes1injuries
ELECTRICAL SYSTEM:IGNITION
4
ELECTRICAL SYSTEM:IGNITION:SWITCH
4
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC
4
POWER TRAIN:AUTOMATIC TRANSMISSION
3
Total complaints124
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Condensed version: @ 70mph posted speed limit goodyear allegra touring tire exploded like a 1/4 stick of dynamite and almost cost me my life if my reactionary time had been any slower. 3 other tires same leaking through sidewall goodyear decorative gills on same this has not resolved. Seller has…”
“Condensed version: @ 70mph posted speed limit goodyear allegra touring tire exploded like a 1/4 stick of dynamite and almost cost me my life if my reactionary time had been any slower. 3 other tires same leaking through sidewall goodyear decorative gills on same this has not resolved. Seller has…”
“I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major ford dealer (brandon ford), and they are refusing to help me. I called ford customer service and he said my vin is not listed for a recall, but yet had no answer…”
“12/6/2014 @ 18:20 c.s.t. To whom it may concern, (hopefully a supervisor or director) the drivers side seat belt floor clasp fails. I releases the seat belt while driving. After two or three times of re-hooking the seat-belt to the hold down clasp bolted through floor board of the vehicle, it will…”
“Tl* the contact owns a 1996 ford aerostar. While driving approximately 50 mph the front drivers side tire began to vibrate. The vehicle was taken to an independent mechanic. The technician stated the transfer case would have to be replaced. The vehicle was not repaired. Nhtsa recall campaign id…”
“Tl*the contact owns a 1996 ford aerostar. While driving 50 mph, the contact heard a loud roaring sound. She stopped the vehicle and noticed that the rear passenger wheel spokes failed. The wheel was replaced with a spare tire. There was no damage to the tire or vehicle. The wheel was inspected by…”
“Dt*: the contact stated while the vehicle was being driven 30 mph, all power failed and the engine stalled. The stalling has also occurred at higher speeds and while the vehicle was immobile. A fuse connected to the battery cables blew. When the fuse was replaced, the engine would restart. The…”
“Dt*: the contact stated the vehicle was taken to a tire dealer for replacement of the tires. After the tires were replaced and vehicle was being driven home at 45mph, the vehicle hesitated as if the gears were not changing properly. The vehicle was returned to the tire dealer who determined the…”
Defect investigations
InvestigationEA99002 Opened 1999-01-07 · closed 2000-11-14
TRANSFER CASES AND REAR DRIVE SHAFT
There is no summary currently available
InvestigationRQ98012 Opened 1998-07-31 · closed 1999-01-07
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1996 Ford Aerostar as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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