Sign inCreate free garage
Research · Vans

1996 Ford AerostarRecalls, problems, MPG & safety

NHTSA lists 6 safety recalls and 104 owner complaints for the 1996 Ford Aerostar. Most complaints involve wheels (23) and service brakes, hydraulic (15). The EPA rates it 15–18 mpg combined.

Check a VINAdd to my garage
Combined MPG
15–18mpg
EPA · 4 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
6campaigns
Latest Mar 2006
Owner complaints
104
Top: wheels
Fuel cost / yr
$3,550est.
EPA estimate, best version
01 —Recalls

Safety recalls

6 NHTSA campaigns · applies to some vehicles, check your VIN

Service brakes, hydraulic

Free remedy

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.

Service brakes, hydraulicReported Mar 13, 2006NHTSA 06E022000

Electrical system: switch

Free remedy

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.

Electrical systemReported Feb 9, 1999NHTSA 99V029000

Service brakes

Free remedy

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.

Service brakes, airReported Apr 8, 1998NHTSA 98E010000
See all 6 recalls with remedies
Data from NHTSA Recalls API · synced Oct 30, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

104 complaints filed with NHTSA · May 1996 – Mar 2020
  1. Wheels23
  2. Service brakes, hydraulic15
  3. Electrical system12
  4. Power train12
  5. Steering8
  6. Air bags6
  7. Tires5
  8. Latches/locks/linkages5
  9. Structure4

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each Aerostar model year we’ve synced.

View as table
Model yearNHTSA complaints
1996104
199763
Crashes reported
9
Fires reported
4
Injuries reported
7
Deaths reported
0
Data from NHTSA Complaints API · synced Oct 30, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Wheels

23 reports
“CONDENSED VERSION: @ 70MPH POSTED SPEED LIMIT GOODYEAR ALLEGRA TOURING TIRE EXPLODED LIKE A 1/4 STICK OF DYNAMITE AND ALMOST COST ME MY LIFE IF MY REACTIONARY TIME HAD BEEN ANY SLOWER. 3 OTHER TIRES SAME LEAKING THROUGH SIDEWALL GOODYEAR DECORATIVE GILLS ON SAME THIS HAS NOT RESOLVED. SELLER HAS NOT RESOLVED AND REFUSES THOUGH GOODYEAR SAID TO REPLACE BEFORE THE MAIN ISSUE OF THE LEFT FRONT DRIVER TIRE EXPLODING AT 70 MPH, . LITIGATION IS NEXT STEP IF AMICABLE RESOLUTION CAN NOT BE HAD. CONTACT HAS BEEN EXTENSIVE WITH GOODYEAR TO NO RESULTS.”
Owner complaint to NHTSAFiled Mar 11, 2020Structure, WheelsODI 11317548

Service brakes, hydraulic

15 reports4 crashes
“BRAKE ROTORS ARE WEARING, AND WHEN THE CONSUMER APPLIES THE BRAKES, THE VEHICLE WILL JERK AND BECOME HARD FOR THE CONSUMER TO CONTROL. THE DEALER WAS NOTIFIED. *AK THE CONSUMER STATES THAT THIS IS A RESULT OF WARPED FRONT BRAKE DISC. (FORD WON'T PAY) *SCC”
Owner complaint to NHTSAFiled Sep 12, 2002Service brakes, hydraulicODI 8018497

Electrical system

12 reports3 fires
“I HAD SMOKE AND ACRID SMELL COMING FROM UNDER MY DASH (WHILE DRIVING), WHERE THE STEERING COLUMN FITS TO IT. I HAVE CONTACTED A MAJOR FORD DEALER (BRANDON FORD), AND THEY ARE REFUSING TO HELP ME. I CALLED FORD CUSTOMER SERVICE AND HE SAID MY VIN IS NOT LISTED FOR A RECALL, BUT YET HAD NO ANSWER FOR ME WHEN I ASKED WHY IS MY VEHICLE NOT ON THE RECALL LIST, WHEN IT IS IN THE GROUP OF VEHICLES THAT WERE RECALLED AND THAT ARE CATCHING ON FIRE WHILE DRIVING DOWN THE ROAD. OVER 887,000 WERE RECALLED FOR FIRE RELATED PROBLEMS, BUT THEY REFUSE TO EVEN LOOK AT MINE. SO, CAN I KEEP DRIVING IT? I DON'T KNOW IF IT WAS A ONE TIME THING, OR WHAT.....”
Owner complaint to NHTSAFiled Aug 23, 2017Electrical systemFire reportedODI 11019124
All 1996 Aerostar problemsSend a problem to a mechanic on findmechanic.ai
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 30, 2026
04 —Key specs

Engines, transmissions & drive

4 versions rated by the EPA
EPA class
Vans
Engines
3.0L 6-cyl · 4.0L 6-cyl
Transmissions
Automatic 4-spd
Drive
Rear-Wheel Drive · 4-Wheel or All-Wheel Drive
Fuel
Regular Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Oct 30, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
Aerostar Van
Auto 4-spd, 6 cyl, 3.0 L · Rear-Wheel Drive
162218$3,550494
Aerostar Wagon
Auto 4-spd, 6 cyl, 3.0 L · Rear-Wheel Drive
152117$3,800523
Aerostar Wagon
Auto 4-spd, 6 cyl, 4.0 L · Rear-Wheel Drive
152117$3,800523
Aerostar Wagon AWD
Auto 4-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive
131915$4,300592
  • Aerostar Van
    Auto 4-spd, 6 cyl, 3.0 L
    16 city · 22 hwy · $3,550/yr
    18
    mpg comb.
  • Aerostar Wagon
    Auto 4-spd, 6 cyl, 3.0 L
    15 city · 21 hwy · $3,800/yr
    17
    mpg comb.
  • Aerostar Wagon
    Auto 4-spd, 6 cyl, 4.0 L
    15 city · 21 hwy · $3,800/yr
    17
    mpg comb.
  • Aerostar Wagon AWD
    Auto 4-spd, 6 cyl, 4.0 L
    13 city · 19 hwy · $4,300/yr
    15
    mpg comb.
Estimate your fuel costCost of ownership
Data from EPA fueleconomy.gov · synced Oct 30, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

1 tested variant
NHTSA has not published 5-Star Safety Ratings for the 1996 Ford Aerostar as of Oct 30, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Oct 30, 2026Vehicle 3578
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

1996 Aerostar questions

How many recalls does the 1996 Ford Aerostar have?

6 safety recalls as of Oct 30, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 1996 Ford Aerostar problems?

Owners filed 104 complaints with NHTSA. The most-cited components are wheels (23), service brakes, hydraulic (15), electrical system (12). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 1996 Ford Aerostar get?

The EPA rates the 1996 Ford Aerostar at 15–18 mpg combined, depending on engine and drivetrain (4 versions rated).

Data from NHTSA & EPA · synced Oct 30, 2026