VehicleVerdict

1994 Ford Aerostar problems

Verdict · NHTSA data

One of the years to avoid

With 384 complaints filed to NHTSA — about 2.2 times the median Aerostar year — the 1994 model ranks #3 of 16 Aerostar years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include 8 deaths and 42 injuries, per the complaint records themselves.

No single system dominates the record — complaints spread across electrical system (81), transmission (48), and airbags (45), which usually points to general build quality rather than one defect.

384

NHTSA complaints

5

Recalls

5

Investigations

28

Crash-involved

33

Fires reported

42

Injuries

8

Deaths

—

NCAP overall

How does 1994 compare to other Aerostar years?

Aerostar NHTSA complaints by model year, 1994 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, 1994 highlighted. Red bars are years to avoid.

See all Aerostar years to avoid →

What are the most common 1994 Ford Aerostar problems?

ComponentComplaintsShare
Electrical System8121%
Transmission4813%
Airbags4512%
Brakes318%
Engine257%
Steering226%
Fuel System205%
Tires & Wheels164%
Body & Structure164%
Lighting133%
Suspension133%
Seat Belts123%
Speed Control123%
Visibility & Wipers103%
Seats82%
Other82%
Latches & Locks21%
Climate Control (A/C & Heat)21%

Does the 1994 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.

99V028000Electrical SystemFebruary 9, 1999 · 23,097 units

Defect

VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.

Consequence

HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEHICLE FIRE.

Remedy

DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.

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.

“CAR WAS PARKED IN DRIVEWAY, UNTOUCHED, FOR AT LEAST 24 HOURS. FIRE ERUPTED ABOUT 7:00 AM. FLAMES WERE COMING THROUGH THE DRIVERS SIDE WINDSHIELD. SEEMED TO BE ELECTRICAL IN NATURE. CAR IS A TOTAL LOSS. CAR IS COMPLETELY ORIGINAL (NO ELECTRIC ALTERATIONS). CAR HAD BEEN TO THE DEALER WITHIN THE LAST…”

Complaint filed with NHTSA · Electrical System · January 26, 2008 · fire

“WAS DRIVING 7 KIDS IN VEHICLE, GOING ABOUT 45MPH, WHEN TRANSFER CASE WAS LEAKING UNDER NORMAL DRIVING CONDITIONS. ANOTHER TRUCK FORCED AEROSTAR OFF ROAD DUE TO BEING ON FIRE. FLAMES HAD MADE TANK GLOW RED. FLAMES PUT OUT W/FIRE EXTINGUISHER. VEHICLE TOWED TO FORD DEALER. REPAIRS DONE ON TRANSFER…”

Complaint filed with NHTSA · Transmission · March 15, 1995 · fire

“CONSUMER'S VEHICLE WAS INVOLVED IN A HEAD ON COLLISION WHILE GOING THROUGH AN INNER SECTION BETWEEN 25-30 MPH. UPON IMPACT, DRIVER'S SIDE AIR BAG FAILED TO DEPLOY. DRIVER SUSTAINED CHEST INJURIES FROM THE SEAT BELT. MANUFACTURER WANTED TO SEND A FACTORY REPRESENTATIVE TO INVESTIGATE THE CAUSE OF…”

Complaint filed with NHTSA · Airbags · June 30, 2004 · crash

“WHEN DRIVING AT 35 MPH THERE IS SOME POPPING NOISE COMING FROM THE STEERING COLUMN.ALSO, BRAKES ARE WORKING INTERMITTENTLY.CONSUMER TRIED TO AVOID HITTING A DEER WITHIN THE ROAD, AND STEERING WHEEL LOCKED UP, CAUSING THE VEHICEL TO FLIP OVER FOUR TIMES. *AK”

Complaint filed with NHTSA · Brakes · December 9, 1998 · crash

“EA98016; WHILE DRIVING THE VEHICLE STALLED AND A FIRE CAME FROM UNDERNEATH THE VEHICLE. CAUSE UNKNOWN. CURRENTLY AT DEALER. PLEASE PROVIDE DETAILS. *AK”

Complaint filed with NHTSA · Engine · August 4, 1998 · fire

1994 Ford Aerostar — common questions

Is the 1994 Ford Aerostar reliable?

NHTSA data argues against it: 384 complaints put the 1994 model at #3 of 16 Aerostar years. It is one of the Aerostar years to avoid.

What are the most common 1994 Aerostar problems?

According to NHTSA complaint data, the leading problem areas are electrical system (81 complaints), transmission (48 complaints), airbags (45 complaints).

Does the 1994 Ford Aerostar have recalls?

Yes — NHTSA lists 5 recall campaigns affecting the 1994 Ford Aerostar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1994 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.