1993 FORD AEROSTAR — Problems, Recalls & Safety Data

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N/A

Safety Rating

541

Owner Complaints

45 Crashes 49 Fires

4

Recalls

ACTIVE RECALL

1

Service Bulletin

1

Investigation

Overview of the 1993 FORD AEROSTAR

The 1993 FORD AEROSTAR has received a total of 541 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There have been 4 recall campaigns affecting this vehicle, covering issues with SERVICE BRAKES, HYDRAULIC, ELECTRICAL SYSTEM:IGNITION:SWITCH, SERVICE BRAKES, AIR:DISC:ROTOR. 1 technical service bulletin have been issued by Ford Motor Company for this model year. The most commonly reported problems involve the Electrical Systemignitionswitch (48 complaints), Equipmentapplianceair Conditioner (24 complaints), and Air Bagsfrontal (22 complaints).

Recalls for the 1993 FORD AEROSTAR

NHTSA has recorded 4 recalls for the 1993 FORD AEROSTAR, potentially affecting up to 868,141 vehicles.

Recall 06E022000 — SERVICE BRAKES, HYDRAULIC

| 7,440 vehicles affected

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...

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.

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Recall 99V029000 — ELECTRICAL SYSTEM:IGNITION:SWITCH

| 762,201 vehicles affected

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.

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Recall 98E010000 — SERVICE BRAKES, AIR:DISC:ROTOR

| 23,500 vehicles affected

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.

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Recall 97V204000 — POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

| 75,000 vehicles affected

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.

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Owner Complaints for the 1993 FORD AEROSTAR

541 complaints have been filed with NHTSA for the 1993 FORD AEROSTAR. Below is a breakdown by vehicle component.

Electrical Systemignitionswitch
Complaints: 48 14 Fires
Equipmentapplianceair Conditioner
Complaints: 24
Air Bagsfrontal
Complaints: 22 19 Crashes 19 Injuries
Power Trainautomatic Transmissionlever And Linkagecolumn Shift
Complaints: 21 1 Fire
Vehicle Speed Control
Complaints: 19 3 Crashes
Power Trainautomatic Transmission
Complaints: 17 2 Crashes 1 Fire 2 Injuries
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slip
Complaints: 17 3 Crashes 1 Injury
Air Bags
Complaints: 15 4 Crashes 4 Injuries
Electrical Systemignition
Complaints: 13 4 Fires
Electrical Systemwiringinteriorunder Dash
Complaints: 12 7 Fires
Service Brakes Hydraulicfoundation Components
Complaints: 12 3 Crashes
Service Brakes Hydraulicfoundation Componentsdiscrotor
Complaints: 12
Electrical Systemhorn
Complaints: 10
Engine And Engine Coolingenginegasoline
Complaints: 10 4 Fires
Structurebodydoor
Complaints: 10
Engine And Engine Coolingengine
Complaints: 9
Service Brakes Hydraulicfoundation Componentsdisc
Complaints: 9
Tires
Complaints: 9
Latcheslockslinkagesdoorslatch
Complaints: 8 1 Injury
Electrical System
Complaints: 7 3 Fires
Unknown Or Other
Complaints: 7
Electrical Systemwiring
Complaints: 6 3 Fires
Fuel System Gasolinedeliveryfuel Pump
Complaints: 6 2 Fires
Power Traindrivelinedriveshaft
Complaints: 6
Power Trainmanual Transmission
Complaints: 6
Power Traintransfer Case 4 Wheel Drive
Complaints: 6
Service Brakes Hydraulicfoundation Componentshoses Linespiping And Fittings
Complaints: 6
Visibilitypower Window Devices And Controls
Complaints: 6 1 Fire
Service Brakes Hydraulicfoundation Componentsmaster Cylinder
Complaints: 5
Suspensionrear
Complaints: 5
Electrical Systemwiringfront Underhood
Complaints: 4 3 Fires
Engine And Engine Coolingcooling System
Complaints: 4
Fuel System Gasolinestoragetank Assembly
Complaints: 4
Power Trainaxle Assembly
Complaints: 4 1 Crash 1 Injury
Seat Beltsfrontbuckle Assembly
Complaints: 4 2 Crashes 5 Injuries
Service Brakes Hydraulicfoundation Componentsdiscpads
Complaints: 4
Steeringhydraulic Power Assist System
Complaints: 4
Structurebody
Complaints: 4
Suspension
Complaints: 4
Suspensionfront
Complaints: 4
Electrical Systemalternatorgeneratorregulator
Complaints: 3 1 Fire
Electrical Systemstarter Assembly
Complaints: 3 1 Fire
Exterior Lightingbrake Lights
Complaints: 3
Exterior Lightingheadlightsswitch
Complaints: 3 1 Fire
Power Train
Complaints: 3
Power Trainautomatic Transmissionparkneutral Start Interlock Switch
Complaints: 3 2 Crashes 3 Injuries
Seat Beltsfrontanchorage
Complaints: 3
Seat Beltsfrontretractor
Complaints: 3 1 Crash 1 Injury
Seatsfront Assemblyrecliner
Complaints: 3 1 Crash 1 Injury
Service Brakes Hydraulicfoundation Componentsdisccaliper
Complaints: 3
Service Brakes Hydraulicfoundation Componentsdrum
Complaints: 3
Steering Steering Wheelhandle Bar
Complaints: 3
Steeringlinkagestie Rod Assembly
Complaints: 3
Structurebodyhatchbackliftgatesupport Devicestrut
Complaints: 3 1 Injury
Suspensionfrontcontrol Arm
Complaints: 3
Tirestreadbelt
Complaints: 3
Visibilitydefrosterdefoggerhvac Systemheater Core
Complaints: 3
Wheelslugsnutsboltsstuds
Complaints: 3
Electrical System12v24v48v Battery
Complaints: 2
Electrical Systemwiringfuses And Circuit Breakers
Complaints: 2
Engine And Engine Cooling
Complaints: 2
Engine And Engine Coolingexhaust Systemmanifoldheadermufflertail Pipe
Complaints: 2
Exterior Lightingheadlights
Complaints: 2
Fuel System Gasolinedeliveryhoses Linespiping And Fittings
Complaints: 2
Power Trainautomatic Transmissioncooling Unit And Lines
Complaints: 2 1 Fire
Power Trainautomatic Transmissiongear Position Indication Prndl
Complaints: 2
Power Trainaxle Assemblyaxle Shaftseal
Complaints: 2
Power Traindrivelineconstant Velocity Joint
Complaints: 2
Steeringhydraulic Power Assisthose Piping And Connections
Complaints: 2
Steeringhydraulic Power Assistpower Steering Fluid
Complaints: 2
Structurebodytailgatehinge And Attachments
Complaints: 2 1 Injury
Suspensionfrontshock Absorber
Complaints: 2
Suspensionfrontspringscoil Springs
Complaints: 2
Suspensionfrontstabilizer Bar
Complaints: 2
Vehicle Speed Controlcruise Control
Complaints: 2
Visibilitywindshield
Complaints: 2
Air Bagsfrontalsensorcontrol Module
Complaints: 1
Child Seatharness Buckleinfant
Complaints: 1
Engine And Engine Coolingcooling Systemhoseslinespipingfittings
Complaints: 1
Engine And Engine Coolingcooling Systemradiator Assembly
Complaints: 1
Engine And Engine Coolingenginediesel
Complaints: 1
Engine And Engine Coolingenginegasolinebelts And Associated Pulleys
Complaints: 1
Engine And Engine Coolingexhaust System
Complaints: 1
Engine And Engine Coolingexhaust Systememission Control
Complaints: 1
Engine And Engine Coolingexhaust Systememission Controlgas Recirculation Valve Egr Valve
Complaints: 1
Equipment
Complaints: 1
Equipmentelectricalradiotape Deckcd Etc
Complaints: 1
Equipmentmechanicalaccessory Scissorscrewbottle Jacklift
Complaints: 1
Equipmentmechanicalcarrierrack
Complaints: 1
Exterior Lightingheadlightshighlow Beam Dimmer Switch
Complaints: 1
Fuel System Gasoline
Complaints: 1
Latcheslockslinkageshatchbackliftgatelock
Complaints: 1
Parking Brakeconventional
Complaints: 1
Power Traindrivelinedifferential Unit
Complaints: 1
Seat Beltsrearother
Complaints: 1
Service Brakes Airdiscrotor
Complaints: 1
Service Brakes Electric
Complaints: 1
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slipabs Warning Light
Complaints: 1
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slipcontrol Unitmodule
Complaints: 1
Service Brakes Hydraulicbrake Fluid Low Warning Lamp
Complaints: 1
Service Brakes Hydraulicfoundation Componentsdrumwheel Cylinders
Complaints: 1
Service Brakes Hydraulicpedals And Linkages
Complaints: 1
Service Brakes Hydraulicpower Assistvacuum
Complaints: 1
Steering
Complaints: 1
Steeringcolumn
Complaints: 1 1 Crash
Steeringgear Box Other Than Rack And Pinion
Complaints: 1
Steeringgear Boxshaft Sector
Complaints: 1
Steeringlinkages
Complaints: 1
Steeringlinkagesknucklespindlearm
Complaints: 1
Structure
Complaints: 1
Structurebodybumpers
Complaints: 1 1 Crash
Structurebodyhatchbackliftgatehinge And Attachments
Complaints: 1
Structurebodyhood
Complaints: 1
Structurebodytailgate
Complaints: 1
Structureframe And Membersunderbody Shields
Complaints: 1 1 Fire
Suspensionfrontcontrol Armlower Ball Joint
Complaints: 1
Suspensionfrontwheel Bearing
Complaints: 1
Suspensionrearshock Absorber
Complaints: 1
Vehicle Speed Controlaccelerator Pedal
Complaints: 1
Vehicle Speed Controllinkages
Complaints: 1 1 Crash
Vehicle Speed Controlsprings
Complaints: 1 1 Crash
Visibilitywindshield Wiperwasher
Complaints: 1
Visibilitywindshield Wiperwasherswitchwiring
Complaints: 1
Wheels
Complaints: 1 1 Fire

Most Recent Complaints

#10787003 | POWER TRAIN | | N/A miles
TL* THE CONTACT OWNS A 1993 FORD AEROSTAR. WHILE DRIVING AT APPROXIMATELY 80 MPH, THERE WAS A VIBRATION COMING FROM THE DRIVER SIDE AND THERE WAS FLUID LEAKING FROM THE VEHICLE. THE CONTACT NOTICED THAT THE TRANSMISSION TRANSFER CASE WAS FRACTURED AND FLUID WAS LEAKING. THE VEHICLE WAS TOWED TO THE CONTACTS RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.
#10632568 | ELECTRICAL SYSTEM | | 169,000 miles
TL* THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT THE KEY BECAME LODGED IN THE IGNITION. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR A DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 169,000.
#10592183 | STRUCTURE:BODY:BUMPERS | | 100,000 miles Crash
BACKED INTO PINE TREE IN DRIVEWAY. SHATTERED PLASTIC BUMPER COVER. CAN NOT REPLACE BUMPER COVER BECAUSE FORD SAYS OBSOLETE. ALSO NO AFTER MARKET BUMPER CAN BE FOUND FOR THIS MODEL. THIS BUMPER PROTECTS NO ONE. *JS FORD WON'T EVEN GIVE ME THE FORD PART NUMBER. ITS A CARGO VAN. OTHER MODEL COVERS CAN BE BOUGHT FROM AFTER MARKET SELLERS BUT NOT THE CARGO VAN. ONLY PLACE TO GET ONE IS JUNK YARDS IF YOU ARE GET LUCKY. MOST OF THEIR COVERS ARE BUSTED ALSO. A CAR IS A HAZARD WITHOUT A BUMPER. *JS
#10298475 | ELECTRICAL SYSTEM:IGNITION:SWITCH | | 144,670 miles
TL*THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT HE NOTICED ELECTRICAL PROBLEMS. THERE WAS A CLICKING SOUND AND HE COULD FEEL A PULSATION IN THE DASHBOARD; THERE WERE ALSO ELECTRICAL SHORTAGES. HE CALLED THE DEALERSHIP ABOUT RECALL 99V029000 AND WAS TOLD THAT HIS VEHICLE WAS NOT INCLUDED IN THE RECALL. HE ALSO CONSULTED THE MANUFACTURER AND IT WAS CONFIRMED THAT THE VEHICLE WAS NOT INCLUDED. THE VEHICLE HAD NOT BEEN REPAIRED TO-DATE. THE CURRENT MILEAGE WAS 144,705. THE FAILURE MILEAGE WAS APPROXIMATELY 144,670. UPDATED 02/22/11
#10246511 | ELECTRICAL SYSTEM | | 168,000 miles Fire
TL*THE CONTACT OWNS A 1993 FORD AEROSTAR. THE CONTACT STATED THAT HIS VEHICLE WAS 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; THEREFORE, CREATING A SHORT CIRCUIT AND ALLOWING CURRENT TO FLOW THROUGH THE GROUND WIRE. ON NUMEROUS OCCASIONS, HE NOTICED THAT THE SWITCH MODULE MELTED AND THE INSTRUMENT CONTROL PANEL LIGHTING WAS INOPERATIVE. AS A RESULT, THE RISK OF A SEVERE FIRE INCREASED. THE MANUFACTURER STATED THAT THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 99V029000 (ELECTRICAL SYSTEM:IGNITION:SWITCH); THEREFORE, THEY WOULD NOT ASSUME FINANCIAL RESPONSIBILITY FOR THE REPAIR. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 168,000 AND CURRENT MILEAGE WAS 180,000.

View all Electrical Systemignitionswitch complaints →

Safety Rating for the 1993 FORD AEROSTAR

NHTSA has not yet tested the 1993 FORD AEROSTAR in its New Car Assessment Program.

Technical Service Bulletins for the 1993 FORD AEROSTAR

Ford Motor Company has issued 1 technical service bulletin (TSBs) for the 1993 FORD AEROSTAR. TSBs are notices sent by manufacturers to their dealers describing a known issue and the recommended repair procedure.

BC1383950906 — STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

VEHICLE MAY EXHIBIT A MOAN WHEN TURNING - TO CORRECT THIS CONDITION, REPLACE THE HIGH PRESSURE HOSE WITH A TUNED HOSE. *TW

NHTSA Investigations for the 1993 FORD AEROSTAR

NHTSA has opened 1 investigation into potential safety defects in the 1993 FORD AEROSTAR.

Investigation PE98010 — VEHICLE SPEED CONTROL:LINKAGES Closed

Opened:

FUEL SENDER ASSEMBLY FIRES

Other Model Years of the FORD AEROSTAR

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Other FORD Models

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