VehicleVerdict

1996 Ford Aerostar problems

Verdict · NHTSA data

Worth extra scrutiny

The 1996 Ford Aerostar is a recall-heavy year with an otherwise ordinary complaint record: 6 NHTSA recall campaigns apply, yet its 124 owner complaints run below the Aerostar median. The recalls matter more than the complaint count here — verify every campaign was completed before buying.

No single system dominates the record — complaints spread across tires & wheels (28), brakes (23), and transmission (14), which usually points to general build quality rather than one defect.

124

NHTSA complaints

6

Recalls

2

Investigations

13

Crash-involved

4

Fires reported

8

Injuries

0

Deaths

—

NCAP overall

How does 1996 compare to other Aerostar years?

Aerostar NHTSA complaints by model year, 1996 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, 1996 highlighted. Red bars are years to avoid.

See all Aerostar years to avoid →

What are the most common 1996 Ford Aerostar problems?

ComponentComplaintsShare
Tires & Wheels2823%
Brakes2319%
Transmission1411%
Electrical System1411%
Steering97%
Airbags76%
Latches & Locks65%
Speed Control43%
Body & Structure43%
Lighting32%
Seats32%
Engine22%
Other22%
Fuel System22%
Climate Control (A/C & Heat)11%
Seat Belts11%
Suspension11%

Does the 1996 Ford Aerostar have recalls?

6 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.

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.

96V161000OtherAugust 29, 1996 · 134,770 units

Defect

THE CERTIFICATION LABELS ON THE INVOLVED VEHICLES HAS INCORRECT REAR TIRE INFLATION PRESSURE DESIGNATIONS. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Consequence

INCORRECT INFLATION PRESSURES COULD CAUSE PREMATURE WEAR OF THE REAR TIRES. .

Remedy

OWNERS WILL BE PROVIDED WITH CORRECT CERTIFICATION LABELS AND INSTRUCTIONS FOR INSTALLING THESE LABELS. DEALERS CAN INSTALL THIS LABEL IF THE OWNER SO DESIRES.

96V070000Latches & LocksApril 22, 1996 · 73,500 units

Defect

WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."

Consequence

THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.

Remedy

DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.

Consumer complaints filed with NHTSA

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

“BOTH FRONT WHEELS HAVE CRACKS IN THE FORD MANUFACTURED SPOOK WHEELS. FORD CONTACTED AND HAD NO EXPLANATION AND STATED IT IS MY PROBLEM. ONE FORD MECHANIC CONTACTED AND 4 WHEEL SHOPS CONTACTED AND STATED IT APPEARS TO BE A DESIGN FLAW. FORD REPRESENTATIVES HAD NO CONCERN CONCERNING SAFETY ISSUE. AS…”

Complaint filed with NHTSA · Tires & Wheels · August 1, 2001

“WHILE CONSUMER WAS BACKING OUT VEHICLE HIT A STEEL POLE. WITHIN SECOND VEHICLE SUDDENLY ACCELERATED IN A FOWARD POSITION, WHILE DRIVER'S FOOT REMAINED ON BRAKE, VEHICLE HIT THE WALL OF WAREHOUSE. DEALER / MANUFACTURER WERE NOT CONTACTED AT THIS TIME. *AK”

Complaint filed with NHTSA · Brakes · October 23, 1999 · crash

“THE VEHICLE WAS PARKED IN FRONT OF THE RESIDENCE AND IT CAUGHT ON FIRE. DRIVER CALLED THE FIRE DEPARTMENT TO EXTINGUISH THE FIRE. NO INJURIES. VEHICLE WAS TOWED AND TOTALED BY THE INSURANCE COMPANY. *AK”

Complaint filed with NHTSA · Electrical System · January 31, 2005 · fire

“SIMILAR TO SAFETY RECALL # 97S83 FOR WHICH SERVICE WAS PERFORMED, BUT AFFECTING FRONT SHAFT AND TRANSFER CASE INSTEAD OF REAR. HAD SEAL LEAK ON FRONT TRANSFER CASE UNDER 30K MILES WARRANTY. TRANSFER CASE BEARING FAILURE ON FRONT DRIVE SHAFT IN TRANSFER CASE RUINED TRANSFER CASE AT A COST OF…”

Complaint filed with NHTSA · Transmission · December 14, 1998

“THE METAL PORTION OF POWER STEERING FLUID RETURN HOSE AND ONE OF THE METAL LINES TO THE POWER STEERING GEAR BOX/ACTUATOR ARE MOUNTED IN SUCH A MANNER THAT THEY RUB TOGETHER AND OVER TIME RUB AWAY AT THE METAL AND DEVELOP LEAKS THAT CAUSE THE POWER STEERING FLUID TO LEAK OUT CAUSING A CATASTROPHIC…”

Complaint filed with NHTSA · Steering · February 1, 2001

1996 Ford Aerostar — common questions

Is the 1996 Ford Aerostar reliable?

Its record is better than the model's norm: 124 NHTSA complaints, below the typical Aerostar year, with 6 recalls and no open investigations.

What are the most common 1996 Aerostar problems?

According to NHTSA complaint data, the leading problem areas are tires & wheels (28 complaints), brakes (23 complaints), transmission (14 complaints).

Does the 1996 Ford Aerostar have recalls?

Yes — NHTSA lists 6 recall campaigns affecting the 1996 Ford Aerostar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1996 Ford Aerostar under NHTSA investigation?

NHTSA opened 2 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.