VehicleVerdict

1994 Ford Aerostar electrical system problems

The 1994 Ford Aerostar has 81 electrical system complaints filed with NHTSA — 21% of the year's total, and down from the prior model year.

81

Electrical System complaints

21%

Share of year

0

Crash-involved

2

Related recalls

Electrical System complaints by year

Aerostar electrical system complaints by model year111 complaints1986: 24 complaints1987: 44 complaints1988: 50 complaints1989: 104 complaints1990: 61 complaints1991: 77 complaints1992: 71 complaints1993: 111 complaints1994: 81 complaints1995: 43 complaints1996: 14 complaints1997: 17 complaints1998: 1 complaints1999: 1 complaints2000: 1 complaints
Aerostar electrical system complaints by model year. Red bars are years to avoid.

Related recalls

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.

What owners report

“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

Common questions

How many electrical system complaints does the 1994 Ford Aerostar have?

NHTSA has 81 complaints about the 1994 Ford Aerostar electrical system — 21% of all complaints filed for that model year.

Are there recalls for the 1994 Ford Aerostar electrical system?

Yes — 2 NHTSA recall campaigns for this model year are tied to the electrical system: 99V028000, 99V029000.

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.