VehicleVerdict

1992 Ford Aerostar problems

Verdict · NHTSA data

One of the years to avoid

With 439 complaints filed to NHTSA — about 2.6 times the median Aerostar year — the 1992 model ranks #2 of 16 Aerostar years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include 4 deaths and 152 injuries, per the complaint records themselves.

No single system dominates the record — complaints spread across transmission (87), electrical system (71), and brakes (69), which usually points to general build quality rather than one defect.

439

NHTSA complaints

5

Recalls

5

Investigations

38

Crash-involved

42

Fires reported

152

Injuries

4

Deaths

—

NCAP overall

How does 1992 compare to other Aerostar years?

Aerostar NHTSA complaints by model year, 1992 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, 1992 highlighted. Red bars are years to avoid.

See all Aerostar years to avoid →

What are the most common 1992 Ford Aerostar problems?

ComponentComplaintsShare
Transmission8720%
Electrical System7116%
Brakes6916%
Airbags327%
Engine307%
Lighting235%
Steering174%
Visibility & Wipers153%
Tires & Wheels153%
Climate Control (A/C & Heat)143%
Speed Control123%
Body & Structure113%
Fuel System102%
Seat Belts82%
Latches & Locks82%
Suspension82%
Other61%
Seats31%

Does the 1992 Ford Aerostar have recalls?

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

06E022000BrakesMarch 13, 2006 · 7,440 units

Defect

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.

Consequence

LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.

Remedy

AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.

99V094000TransmissionApril 28, 1999 · 10,951 units

Defect

VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). 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. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.

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.

99V029000Electrical SystemFebruary 9, 1999 · 762,201 units

Defect

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 GROUND WIRE.

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.

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.

97V204000TransmissionNovember 13, 1997 · 75,000 units

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. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.

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.

Consumer complaints filed with NHTSA

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

“CONSUMER EXPERIENCED PROBLEM WITH TRANSFER CASE FAILURE. WHILE DRIVING ON THE HIGHWAY DURING APPROXIMATELY 75 MPH, WITH THREE CHILDREN IN THE BACK SEAT, TRANSFER CASE BROKE IN THREE PIECES, CAUSING THE TRANMISSION/DRIVESHAFT & MUFFLER TO DROP AND PUNCTURE A HOLE IN GAS TANK . DEALER NOTIFIED AND…”

Complaint filed with NHTSA · Transmission · June 4, 1998 · fire

“DRIVER'S POWER WINDOW MALFUNCTIONED. IN ADDITION, TRANSMISSION FAILED/ABS LIGHT INTERMITTENTLY COMES ON/MASTER CYLINDER FAILED, CAUSING AN ACCIDENT/AIR CONDITIONING COMPRESSOR FAILED/TIE RODS REPLACED/TAIL LIGHTS REPEATED LY REPLACED/IGNITION SWITCH FAILED, CAUSING A FIRE/REPEATED ENGINE OIL LEAKS…”

Complaint filed with NHTSA · Electrical System · March 31, 1998 · fire

“DRIVER'S POWER WINDOW MALFUNCTIONED. IN ADDITION, TRANSMISSION FAILED/ABS LIGHT INTERMITTENTLY COMES ON/MASTER CYLINDER FAILED, CAUSING AN ACCIDENT/AIR CONDITIONING COMPRESSOR FAILED/TIE RODS REPLACED/TAIL LIGHTS REPEATED LY REPLACED/IGNITION SWITCH FAILED, CAUSING A FIRE/REPEATED ENGINE OIL LEAKS…”

Complaint filed with NHTSA · Brakes · March 31, 1998 · fire

“CONSUMER WAS TRAVELING 20-25 MPH AND INVOLVED IN A HEAD-ON COLLISON, IMPACTING ON FRONT DRIVER'S SIDE IN WHICH DRIVER'S SIDE AIR BAG FAILED TO DEPLOY. CONSUMER HAS CONTACTED DEALER. PLEASE PROVIDE ANY FURTHER DETAILS. *AK CONSUMER INVOLVED IN SIX ACCIDENTS, AIR BAGS FAILED TO DEPLOY ON ALL…”

Complaint filed with NHTSA · Airbags · March 16, 1999 · crash

“DRIVER'S POWER WINDOW MALFUNCTIONED. IN ADDITION, TRANSMISSION FAILED/ABS LIGHT INTERMITTENTLY COMES ON/MASTER CYLINDER FAILED, CAUSING AN ACCIDENT/AIR CONDITIONING COMPRESSOR FAILED/TIE RODS REPLACED/TAIL LIGHTS REPEATED LY REPLACED/IGNITION SWITCH FAILED, CAUSING A FIRE/REPEATED ENGINE OIL LEAKS…”

Complaint filed with NHTSA · Engine · March 31, 1998 · fire

1992 Ford Aerostar — common questions

Is the 1992 Ford Aerostar reliable?

NHTSA data argues against it: 439 complaints put the 1992 model at #2 of 16 Aerostar years. It is one of the Aerostar years to avoid.

What are the most common 1992 Aerostar problems?

According to NHTSA complaint data, the leading problem areas are transmission (87 complaints), electrical system (71 complaints), brakes (69 complaints).

Does the 1992 Ford Aerostar have recalls?

Yes — NHTSA lists 5 recall campaigns affecting the 1992 Ford Aerostar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1992 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.