Problems · NHTSA complaints

1996 Ford Aerostar problems

Owners filed 104 complaints about the 1996 Ford Aerostar with NHTSA between May 1996 and Mar 2020. The most-cited component is wheels (23).

Complaints
104
Filed with NHTSA
Crashes
9
Reported by owners
Fires
4
Reported by owners
Injuries
7
People reported injured
Deaths
0
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  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
  10. Vehicle speed control4
  11. Seats3
  12. Equipment3
  13. Engine and engine cooling2
  14. Exterior lighting2

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

Data from NHTSA Complaints API · synced Oct 30, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
19966
199717
199814
199919
200010
200110
20028
20036
20044
20052
20063
20071
20080
20090
20100
20111
20120
20130
20141
20150
20160
20171
20180
20190
20201

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

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 crashes1 related recall
“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 fires1 related recall
“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

Power train

12 reports1 related recall
“TL* THE CONTACT OWNS A 1996 FORD AEROSTAR. WHILE DRIVING APPROXIMATELY 50 MPH THE FRONT DRIVERS SIDE TIRE BEGAN TO VIBRATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN STATED THE TRANSFER CASE WOULD HAVE TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. NHTSA RECALL CAMPAIGN ID NUMBER: 97V204000 (POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)) MAY BE RELATED TO THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THE VIN WAS NOT INCLUDED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.”
Owner complaint to NHTSAFiled Sep 13, 2011Power trainODI 10425204

Steering

8 reports
“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 FAILURE OF THE POWER STEERING. THE ONLY INDICATION OF THIS FAILURE IS WHINING COMING FROM THE ENGINE COMPARTMENT.*AK”
Owner complaint to NHTSAFiled Feb 11, 2001SteeringODI 740741

Air bags

6 reports6 crashes
“IN A MULTIPLE CAR PILE-UP, WITH SPEEDS BETWEEN 35 AND 50 MPH THE DRIVER'S AIRBAG IN OUR VAN (VEHICLE NUMBER #3 OF 4 INVOLVED) DID NOT DEPLOY. OUR VEHICLE WAS DAMAGED ACROSS THE ENTIRE FRONT AND THE ENTIRE BACK BUMPERS (GRILL, HATCH...). MY DAUGHTER WAS EXAMINED BY A PHYSICIAN AND MISSED SOME WORK. IF THE AIRBAG HAD DEPLOYED SHE SHOULD HAVE RECEIVED SOME PROTECTION.*AK”
Owner complaint to NHTSAFiled Sep 19, 2004Air bagsCrash reportedODI 10091293
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 30, 2026

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