Verdict · NHTSA data
One of the years to avoid
With 282 complaints filed to NHTSA — about 1.6 times the median Aerostar year — the 1991 model ranks #5 of 16 Aerostar years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include one death and 31 injuries, per the complaint records themselves.
Electrical System leads the complaint categories with 77 reports (27% of the total).
282
NHTSA complaints
4
Recalls
2
Investigations
28
Crash-involved
78
Fires reported
31
Injuries
1
Deaths
—
NCAP overall
| Component | Complaints | Share | vs prior year |
|---|---|---|---|
| Electrical System | 77 | 27% | ▲ up |
| Transmission | 56 | 20% | ▲ up |
| Brakes | 41 | 15% | — flat |
| Speed Control | 23 | 8% | ▲ up |
| Engine | 14 | 5% | ▼ down |
| Body & Structure | 10 | 4% | ▲ up |
| Climate Control (A/C & Heat) | 9 | 3% | ▲ up |
| Visibility & Wipers | 8 | 3% | — flat |
| Other | 8 | 3% | ▲ up |
| Latches & Locks | 7 | 2% | ▲ up |
| Steering | 7 | 2% | — flat |
| Suspension | 5 | 2% | — flat |
| Fuel System | 4 | 1% | ▼ down |
| Lighting | 4 | 1% | ▲ up |
| Tires & Wheels | 4 | 1% | — flat |
| Seats | 3 | 1% | — flat |
| Seat Belts | 2 | 1% | ▼ down |
4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.
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.
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.
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.
Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.
“THIS VEHICLE WAS DRIVEN FOR 20 MINUTES WHEN A STRONG ODOR OF PLASTIC BURNING WAS SMELLED. THIS VEHICLE WAS PARKED WHEN WHITE SMOKE WAS NOTICED COMING OUT FROM UNDER THE HOOD. A FEW SECONDS PASSED WHEN THE VEHICLE CAUGHT FIRE AND WAS TOTALLY INVOLVED. THIS VEHICLE WAS TOTALED. *AK”
“CONSUMER PARKED VEHICLE IN THE GARAGE, GOT OUT AND TOOK THE KEY OUT OF THE IGNITION. ACCIDENTLY, LEFT THE GEAR IN REVERSE. CONSUMER THEN LEANED AGAINST THE VEHICLE AND IT BEGAN ROLLING BACKWARDS. THE VEHICLE HIT THE SIDE OF THE CARPORT AND STOPPED. CONSUMER CONTACTED THE DEALER AND WAS TOLD THAT'S…”
“UPON SHIFTING GEAR INTO DRIVE WITH CRUISE CONTROL ON, VEHICLE SUDDENLY ACCELERATED. LOST CONTROL AND WENT THROUGH A BUILDING. DRIVER HAD FOOT ON THE BRAKES, BUT THEY FAILED TO STOP VEHICLE. INSURANCE COMPANY INSPECTED THE VEHICLE AND SAID THAT RAIN GOT INTO THE CRUISE CONTROL BOX, CAUSING IT TO…”
“UPON SHIFTING GEAR INTO DRIVE WITH CRUISE CONTROL ON, VEHICLE SUDDENLY ACCELERATED. LOST CONTROL AND WENT THROUGH A BUILDING. DRIVER HAD FOOT ON THE BRAKES, BUT THEY FAILED TO STOP VEHICLE. INSURANCE COMPANY INSPECTED THE VEHICLE AND SAID THAT RAIN GOT INTO THE CRUISE CONTROL BOX, CAUSING IT TO…”
“BEING PARKED FOR ABOUT A HALF AN HOUR THE VEHICLE HAD A SMALL EXPLOSION AND CAUGHT ON FIRE ON THE PASSENGER'S SIDE/ UNDERNEATH THE VEHICLE AND THROUGH THE DASH PANEL. NO PRIOR PROBLEMS WITH THE VEHICLE. CAUSE UNKNOWN. PLEASE PROVIDE DETAILS. *AK”
NHTSA data argues against it: 282 complaints put the 1991 model at #5 of 16 Aerostar years. It is one of the Aerostar years to avoid.
According to NHTSA complaint data, the leading problem areas are electrical system (77 complaints), transmission (56 complaints), brakes (41 complaints).
Yes — NHTSA lists 4 recall campaigns affecting the 1991 Ford Aerostar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.
NHTSA opened 2 investigations into this model year; all are now closed.
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.
Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.
Compiled by Sharon Ben-Moshe, Founder.