VehicleVerdict

1990 Ford Aerostar problems

Verdict · NHTSA data

Worth extra scrutiny

The 1990 Ford Aerostar sits mid-pack among Aerostar years: 254 NHTSA complaints against a model median of roughly 172, with 7 recalls and 5 closed investigations. Complainants reported 25 injuries in total across these filings.

No single system dominates the record — complaints spread across electrical system (61), transmission (37), and brakes (35), which usually points to general build quality rather than one defect.

254

NHTSA complaints

7

Recalls

5

Investigations

32

Crash-involved

65

Fires reported

25

Injuries

0

Deaths

—

NCAP overall

How does 1990 compare to other Aerostar years?

Aerostar NHTSA complaints by model year, 1990 highlighted541 complaints1985: 0 complaints1986: 72 complaints1987: 140 complaints1988: 230 complaints1989: 328 complaints1990: 254 complaints1991: 282 complaints1992: 439 complaints1993: 541 complaints1994: 384 complaints1995: 204 complaints1996: 124 complaints1997: 83 complaints1998: 4 complaints1999: 13 complaints2000: 11 complaints
Aerostar NHTSA complaints by model year, 1990 highlighted. Red bars are years to avoid.

See all Aerostar years to avoid →

What are the most common 1990 Ford Aerostar problems?

ComponentComplaintsShare
Electrical System6124%
Transmission3715%
Brakes3514%
Engine2911%
Fuel System2811%
Speed Control177%
Visibility & Wipers83%
Steering83%
Seat Belts62%
Body & Structure42%
Suspension42%
Tires & Wheels42%
Seats31%
Latches & Locks31%
Other31%
Climate Control (A/C & Heat)31%
Lighting10%

Does the 1990 Ford Aerostar have recalls?

7 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

98V190000Fuel SystemAugust 11, 1998 · 140,000 units

Defect

VEHICLE DESCRIPTION: MINI VANS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA (10 SOUTHERN COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN), FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NEVADA (CLARK COUNTY), OKLAHOMA, SOUTH CAROLINA, AND TEXAS, AND IN THE U.S. TERRITORIES COVERED BY THE FEDERAL STATUTES. THE UPPER PORTION OF THE FUEL TANK CAN DEVELOP SMALL CRACKS DUE TO EXTENDED EXPOSURE TO VERY HIGH AMBIENT TEMPERATURES. FUEL VAPOR OR LEAKAGE COULD OCCUR AT THESE CRACKS.

Consequence

IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.

Remedy

DEALERS WILL REPLACE THE FUEL TANK, REGARDLESS OF MILEAGE, THROUGH MARCH 31, 2002. THIS COVERAGE WILL ONLY BE FOR STRUCTURAL CRACKS AT THE TOP OF THE TANK AND WILL NOT INCLUDE OTHER DAMAGE CAUSED BY AN ACCIDENT OR ROAD DEBRIS.

98E010000BrakesApril 8, 1998 · 23,500 units

Defect

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.

Consequence

LOSS OF BRAKING CAN RESULT.

Remedy

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.

96V071000Electrical SystemApril 25, 1996 · 7,900,000 units

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.

91V189000TransmissionNovember 4, 1991 · 792,000 units

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.

91V164000Seat BeltsSeptember 20, 1991 · 4,842 units

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.

90V144000SeatsAugust 6, 1990 · 14,300 units

Defect

THE SECOND ROW RIGHT HAND SEAT ASSEMBLY HAS A TILT FORWARD FUNCTION. A LATCH RETAINS THE SEAT IN THE NORMAL RIDE POSTION, AND THIS LATCH MAY RELEASE UNDER SEVERE FRONTAL IMPACT CONDITIONS, ALLOWING THE SEAT TO PIVOT FORWARD.

Consequence

IN THE EVENT OF VEHICLE ACCIDENT, THE SEAT COULD PIVOTFORWARD, INCREASING THE RISK OF INJURY TO THE OCCUPANT.

Remedy

REPLACE SEAT PAWL ASSEMBLY WITH A REVISED DESIGN ASSEMBLY.

89V223000BrakesDecember 11, 1989 · 30,000 units

Defect

INABILITY TO MAINTAIN PRESSURE IN THE SECONDARY SYSTEM OF THE MASTER CYLINDER (CONTROLS BRAKING OF REAR WHEELS) COULD INCREASE BRAKE PEDAL TRAVEL AND REDUCE BRAKE PERFORMANCE AT TEMPERATURES LESS THAN 40 DEGREES.

Consequence

THIS WOULD CAUSE REDUCED BRAKING EFFECTIVENESS ANDINCREASED STOPPING DISTANCE THAT COULD RESULT IN A CRASH OR COLLISION.

Remedy

INSTALL NEW DESIGN MASTER CYLINDER INCORPORATING A REDESIGNED SEAL.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“WHILE DRIVING IGNITION SWITCH EXPERIENCED A SHORT CIRCUIT, CAUSING A FIRE UNDER THE HOOD. OWNER WILL CONTACT A DEALER AND OR THE MANUFACTURER. *AKACCORDING TO FORD MOTOR CO., THE IGNITION SWITCH WAS REPLACED IN FEBURARY OF THIS YEAR. SO THE FIRE WAS PROBABLY NOT CAUSED BY THE IGNITION SWITCH, BUT…”

Complaint filed with NHTSA · Electrical System · August 28, 1997 · fire

“UPON STARTING THE VEHICLE, IT ACCELERATED AT A HIGH SPEED AND CRASHED INTO A BUILDING. THE DRIVER'S FOOT WAS ON THE BRAKE PEDAL WHEN SUDDEN ACCELERATION OCCURRED. THE VEHICLE WAS TOTALED. THE INSURANCE COMPANY INDICATED THAT THE INCIDENT WAS INCONCLUSIVE. THERE WAS A TRANSMISSION RECALL 91V189000,…”

Complaint filed with NHTSA · Transmission · May 14, 2004 · crash

“BRAKES FAILED CAUSING CONSUMER TO PLOW THROUGH GARAGE AND INTO FAMILY ROOM FURNISHINGS. NO BODILY INJURIES. TT CONSUMER STATES MECHANIC ADVISED HER THAT THE MASTER CYLINDER HAD FALLEN OUT IN THE MECHANIC'S HAND AND OIL HAD GOT INTO THE BOOSTER MASTER CYLINDER AND BOOSTER WERE REPLACED. *JB ”

Complaint filed with NHTSA · Brakes · December 13, 1995 · crash

“VAN JUST DIED OUT. THEN ALL OF A SUDDEN THE VAN STARTED TO FILL WITH SMOKE AND FIRE AND BURSTED INTO FLAMES. FIRE BELIEVED TO HAVE STARTED IN THE ENGINE. THE FIRE WAS PUT OUT BY THE FIRE DEPARTMENT. VAN HAD OVER $5,000.00 DOLLARS WORTH OF DAMAGE. THE VAN HAS BEEN TOTALLED. FIRE DEPARTMENT STATED…”

Complaint filed with NHTSA · Engine · July 19, 1998 · fire

“WHILE DRIVING AT 55 MPH SMOKE WAS NOTICED COMING IN THE WINDOWS. CONSUMER PULLED TO THE SIDE TO SEE WHAT THE PROBLEM WAS, AND NOTICED THAT FIRE WAS COMING FROM THE BOTTOM OF THE VEHICLE. THE VEHICLE BURST INTO FLAMES, AND THE VEHICLE WAS A TOTAL LOSS. THE FIRE DEPARTMENT HAD TO COME AND PUT THE…”

Complaint filed with NHTSA · Fuel System · fire

1990 Ford Aerostar — common questions

Is the 1990 Ford Aerostar reliable?

It is close to typical for the Aerostar: 254 NHTSA complaints, 7 recalls, and 5 investigations on file.

What are the most common 1990 Aerostar problems?

According to NHTSA complaint data, the leading problem areas are electrical system (61 complaints), transmission (37 complaints), brakes (35 complaints).

Does the 1990 Ford Aerostar have recalls?

Yes — NHTSA lists 7 recall campaigns affecting the 1990 Ford Aerostar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1990 Ford Aerostar under NHTSA investigation?

NHTSA opened 5 investigations into this model year; all are now closed.

Which Ford Aerostar years should you avoid?

Based on complaint rates and open investigations, the Aerostar years to avoid are 1993, 1992, 1994, 1989, 1991. The cleanest record among Aerostar years belongs to 1985.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.