Total Complaints
328 filings
FORD AEROSTAR · model year
328 NHTSA complaints, 26 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1989FORDAEROSTAR carries 328 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 26 crashes, 92 fires, 28 injuries, and 4 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1989 AEROSTAR is fuel system, gasoline:storage:tank assembly with 47 filings, followed by electrical system:ignition:switch (43) and seat belts:front:buckle assembly (20). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.
NHTSA currently has 177 investigation files overlapping the 1989 AEROSTAR, and 8 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
328 filings
Crashes Reported
26 reports
Source
NHTSA ODI
Federal complaints database
Above median complaint volume — review patterns below.
| Component | Count |
|---|---|
| FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY | 47 |
| ELECTRICAL SYSTEM:IGNITION:SWITCH | 43 |
| SEAT BELTS:FRONT:BUCKLE ASSEMBLY | 20 |
| ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH | 16 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 14 |
| ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 12 |
| ELECTRICAL SYSTEM:IGNITION | 12 |
| POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH | 11 |
| VEHICLE SPEED CONTROL | 11 |
| ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR | 9 |
| ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD | 8 |
| ENGINE AND ENGINE COOLING:ENGINE | 7 |
| ELECTRICAL SYSTEM:WIRING | 7 |
| FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP | 5 |
| TIRES | 5 |
MY FORD AEROSTAR CAUGHT FIRE LAST NIGHT FOR NO APPARENT REASON. MY DAUGHTER HAD RETURNED FROM SCHOOL AND PARKED IT IN THE DRIVEWAY. APPROXIMATELY 2 HOURS LATER, A NEIGHBOR RANG THE DOOR BELL AND FRANTICALLY SAID "YOUR VAN IS ON FIRE". WE CALLED 911 AND THE FIRE DEPARTMENT WAS THERE WITHIN 3 MINUTES TO PUT IT OUT. *JB
Mileage: 155,000
BRAKE LINE NEXT TO GAS TANK FAILED ON HIGHWAY, BRAKING ABILITY WAS GREATLY REDUCED. *JB
Mileage: 244,000
DT: THE CONTACT RECEIVED NHTSA RECALL 96V071000 CONCERNING THE IGNITION SWITCH. WHEN HE CONTACTED FORD, THEY COULD NOT FIND THE VIN. THIS STARTED A COUPLE OF MONTHS AGO. THE SWITCH STARTED TO COME APART, CAUSING THE VEHICLE NOT TO START. HE REPAIRED IT HIMSELF, AND IT IS CURRENTLY WORKING.*AK UPDATED 12/27/2005. *NM
Mileage: 208,000
THE CONSUMER STATED THAT BACK IN 1998 SHE HAD A ACCIDENT WITH HER FORD AEROSTAR. SHE STATED THAT WHEN SHE PULLED INTO A PARKING SPACE AND HIT THE BRAKES, THE VEHICLE SURGED FORWARD AND HIT A BUILDING. SHE SAID SHE HAD THE VEHICLE TOWED TO THE DEALER WHO STATED THAT THEY THOUGHT THE PROBLEM WAS A FAULTY IDLE AIR CONTROL. SHE SAID IT WAS REPAIRED AND SHE TOOK THE PART AND SENT IT TO THE MANUFACTURER. NOW THE PROBLEM HAS COME UP AGAIN AND SHE WAS ASKED TO BE A WITNESS, BECAUSE SOMEONE WAS KILLED, WHEN THEIR VEHICLE DID THE SAME THING. *JB IT WAS DETERMINED THAT THE THROTTLE AIR BY PASS VALVE ASSEMBLY WAS NOT ONE OF FORD'S PARTS.
Mileage: 102,371
THE CONSUMER STATED THAT BACK IN 1998 SHE HAD A ACCIDENT WITH HER FORD AEROSTAR. SHE STATED THAT WHEN SHE PULLED INTO A PARKING SPACE AND HIT THE BRAKES, THE VEHICLE SURGED FORWARD AND HIT A BUILDING. SHE SAID SHE HAD THE VEHICLE TOWED TO THE DEALER WHO STATED THAT THEY THOUGHT THE PROBLEM WAS A FAULTY IDLE AIR CONTROL. SHE SAID IT WAS REPAIRED AND SHE TOOK THE PART AND SENT IT TO THE MANUFACTURER. NOW THE PROBLEM HAS COME UP AGAIN AND SHE WAS ASKED TO BE A WITNESS, BECAUSE SOMEONE WAS KILLED, WHEN THEIR VEHICLE DID THE SAME THING. *JB IT WAS DETERMINED THAT THE THROTTLE AIR BY PASS VALVE ASSEMBLY WAS NOT ONE OF FORD'S PARTS.
Mileage: 102,371
NHTSA RECALL 98V190000 CONCERNING FUEL SYSTEM STORAGE TANK ASSEMBLY: CONSUMER INTERMITTENTLY SMELLED A STRONG ODOR OF GASOLINE ON THE OUTSIDE OF THE VEHICLE. T CONSUMER EXAMINED THE GAS TANK AND FOUND THAT FUEL WAS LEAKING FROM THE TOP OF THE TANK WHEN IT WAS FULL. MANUFACTURER CLAIMED THAT THIS VEHICLE WAS NOT A PART OF THE RECALL.*AK
Mileage: 175,000
THE MANUFACTURER WAS REFUSING TO HONOR RECALL 98V190000 FOR FUEL TANK CRACKS BECAUSE THE WARRANTY PERIOD ENDED. *AK
Mileage: 160,000
WE OWE A 1989 FORD AEROSTAR MINI-VAN THE LONG EDITION. WE HAVE HAD IT A LITTLE OVER YEAR. WE HAVE BEEN HAVING A SERIOUS PROBLEM WITH THIS VECHICLE STALLING WHEN DRIVING ON THE HIGHWAY TO AND FROM WORK. IT HAPPENS A LOT MORE OFTEN WHEN IT IS COLD AS OPPOSED TO WHEN IT IS WARMER. *JB
ON JULY 2, 2002 THE TREAD CAME OFF THE TIRE WHILE ON THE FREEWAY. THE TIRE HAD 49,000 MILES ON IT AND IT WAS WARRANTIED FOR 80,000. IT CAUSED $2,700 IN DAMAGE. BRIDGESTONE CLAIMS THE TIRE WAS OPERATED W/ LOW AIR PRESSURE, THIS IS NOT TRUE! THE FRONT TIRES WERE REPLACED BY PEP BOYS 6 MONTHS PRIOR DUE TO TREAD SEPARATION. I AM HAVING BRIDGESTONE SEND ME THE TIRE BACK. I DO HAVE PHOTOS OF THE TIRE AND VAN DAMAGE. TS
CONSUMER STATES THAT THERE IS A CRACK IN THE FUEL TANK WHICH IS NOT ALLOWING THE CONSUMER TO FILL UP A FULL TANK OF GAS. CONTACTED DEALER AND THE DEALER STATED THAT THE WARRENTY PERIOD FOR THE RECALL HAS EXPIRED. MR
CONSUMER NOTICED GAS LEAK IN TANK.*AK
CONSUMER STATES ENGINE WAS ON AND IN THE PARK POSITION, CONSUMER PRESSED BRAKE TO PUT VEHICLE INTO REVERSE AND VEHICLE TOOK OFF IN REVERSE. CONSUMER STATES VEHICLE HIT TWO PARKED CARS AND WAS TOTALLED. PLEASE PROVIDE ANY FURTHER INFORMATION.*JB
TODAY MY WIFE WAS DRIVING OUR 1989 AEROSTAR AND SHE HAD THE ACCELERATOR GO DOWN UNDER HER FOOT BY IT'S SELF FOR NO PERCIEVED REASON. SO I STARTED TO LOOK ON INTERNET TO SEE IF ANYONE ELSE HAD THIS PROBLEM. DEALER CLAIMS NEVER HEARD OF IT! IT SEEMS LIKE I REMEMBERED WATCHING 20/20 OR THAT CANADIAN PROGRAM AND THEY REPORTING ABOUT FORD CRUISE CONTROLS HAVING POWER ON AT ALL TIME AND THAT MOISTER PRESENT AT WIRE HARNESS PLUG THAT CONNECTS THOUGH FIRE WALL COULD CAUSE CRUISE CONTROL TO SUDDEN ACCELLERATE. *AK
TODAY MY WIFE WAS DRIVING OUR 1989 AEROSTAR AND SHE HAD THE ACCELERATOR GO DOWN UNDER HER FOOT BY IT'S SELF FOR NO PERCIEVED REASON. SO I STARTED TO LOOK ON INTERNET TO SEE IF ANYONE ELSE HAD THIS PROBLEM. DEALER CLAIMS NEVER HEARD OF IT! IT SEEMS LIKE I REMEMBERED WATCHING 20/20 OR THAT CANADIAN PROGRAM AND THEY REPORTING ABOUT FORD CRUISE CONTROLS HAVING POWER ON AT ALL TIME AND THAT MOISTER PRESENT AT WIRE HARNESS PLUG THAT CONNECTS THOUGH FIRE WALL COULD CAUSE CRUISE CONTROL TO SUDDEN ACCELLERATE. *AK
THE VEHICLE WAS PARKED FOR APPROXIMATELY 30 MINUTES. IT HAD BEEN RUNNING PERFECTLY WELL. I NOTICED A MINOR TRIPLE CLICK NOISE WHEN I TURNED OFF THE IGNITION BUT DIDN'T THINK MUCH OF ANYTHING OF IT. AFTER SITTING OFF FOR 30-45 MINUTES, THE VEHICLE WAS IN FLAMES HAVING STARTED FROM SOMEWHERE IN THE FRONT OF THE VEHICLE. THIS APPEARS TO BE CONSISTENT WITH REPORTS OF THE IGNITION SWITCH ISSUE. WE WERE NOT AWARE OF THE RECALL PRIOR TO LOOKING FOR IT AFTER OUR VEHICLE WAS DESTROYED. FIREMEN INDICATE THAT THE FIRE STARTED IN THE FRONT PART OF THE VEHICLE, BUT THEY COULD NOT DETERMINE WHY DUE TO THE EXTENT OF THE DAMAGE. BEST WAY TO CONTACT ME IS VIA CELLPHONE AT 706-399-7825.*AK
RECAL 96 V 071 000/ ELECTRICAL IGNITION SYSTEM: AFTER STARTING VEHICLE, ENGINE RACES AND VEHICLE OVERHEATS AND SMOKES. HOWEVER, THIS VEHICLE WAS NOT INCLUDED IN RECALL. *AK THE MOTOR CONTINUE TO RUN AFTER THE IGNITION WAS TURNED OFF AND THE KEY WAS REMOVED. *YH
THE ALTERNATOR FAILED SHORT CIRCUIT. MASSIVE AMOUNTS OF CURRENT PASSED FROM THE BATTERY THROUGH THE ALTERNATOR, WHICH BURST INTO FLAMES. THE FAULT CAUSED THE ENGINE TO STALL DUE TO LACK OF IGNITION AND IT WAS EXTREMELY DIFFICULT TO STEER AND STOP THE VEHICLE AS A RESULT OF LOSS OF POWER STEERING AND POWER BRAKES. SMOKE WAS POURING FROM THE FRONT OF THE VEHICLE. WHEN I MANAGED TO STOP AND OPEN THE HOOD, THE ALTERNATOR, WHICH WAS GLOWING RED INSIDE, BURST INTO FLAMES AND SET FIRE TO CABLES AND RUBBER HOSES AROUND IT. I RECEIVED BURNS TO MY HANDS TRYING TO PUT THE FIRE OUT. LUCKY FOR ME ANOTHER MOTORIST STOPPED AND HE HAD AN EXTINGUISHER. I HAVE NOW HAD TWO FIRES OF THIS TYPE, ONE ON EACH OF MY VEHICLES. YESTERDAY I WENT TO AN ALTERNATOR REMANUFACTURING COMPANY HERE IN MONTERREY, AND THE MANGER TOLD ME THAT HE HAS HAD FIVE ENGINE BAY FIRES IN AEROSTAR MINIVANS IN RECENT MONTHS. IN THE 'GOOD OLD DAYS' UNDERSTAND THERE WAS A FUSIBLE LINK BETWEEN THE ALTERNATOR CHARGING LINE AND THE BATTER
THE ALTERNATOR FAILED SHORT CIRCUIT. MASSIVE AMOUNTS OF CURRENT PASSED FROM THE BATTERY THROUGH THE ALTERNATOR, WHICH BURST INTO FLAMES. THE FAULT CAUSED THE ENGINE TO STALL DUE TO LACK OF IGNITION AND IT WAS EXTREMELY DIFFICULT TO STEER AND STOP THE VEHICLE AS A RESULT OF LOSS OF POWER STEERING AND POWER BRAKES. SMOKE WAS POURING FROM THE FRONT OF THE VEHICLE. WHEN I MANAGED TO STOP AND OPEN THE HOOD, THE ALTERNATOR, WHICH WAS GLOWING RED INSIDE, BURST INTO FLAMES AND SET FIRE TO CABLES AND RUBBER HOSES AROUND IT. I RECEIVED BURNS TO MY HANDS TRYING TO PUT THE FIRE OUT. LUCKY FOR ME ANOTHER MOTORIST STOPPED AND HE HAD AN EXTINGUISHER. I HAVE NOW HAD TWO FIRES OF THIS TYPE, ONE ON EACH OF MY VEHICLES. YESTERDAY I WENT TO AN ALTERNATOR REMANUFACTURING COMPANY HERE IN MONTERREY, AND THE MANGER TOLD ME THAT HE HAS HAD FIVE ENGINE BAY FIRES IN AEROSTAR MINIVANS IN RECENT MONTHS. IN THE 'GOOD OLD DAYS' UNDERSTAND THERE WAS A FUSIBLE LINK BETWEEN THE ALTERNATOR CHARGING LINE AND THE BATTER
THE ALTERNATOR FAILED SHORT CIRCUIT. MASSIVE AMOUNTS OF CURRENT PASSED FROM THE BATTERY THROUGH THE ALTERNATOR, WHICH BURST INTO FLAMES. THE FAULT CAUSED THE ENGINE TO STALL DUE TO LACK OF IGNITION AND IT WAS EXTREMELY DIFFICULT TO STEER AND STOP THE VEHICLE AS A RESULT OF LOSS OF POWER STEERING AND POWER BRAKES. SMOKE WAS POURING FROM THE FRONT OF THE VEHICLE. WHEN I MANAGED TO STOP AND OPEN THE HOOD, THE ALTERNATOR, WHICH WAS GLOWING RED INSIDE, BURST INTO FLAMES AND SET FIRE TO CABLES AND RUBBER HOSES AROUND IT. I RECEIVED BURNS TO MY HANDS TRYING TO PUT THE FIRE OUT. LUCKY FOR ME ANOTHER MOTORIST STOPPED AND HE HAD AN EXTINGUISHER. I HAVE NOW HAD TWO FIRES OF THIS TYPE, ONE ON EACH OF MY VEHICLES. YESTERDAY I WENT TO AN ALTERNATOR REMANUFACTURING COMPANY HERE IN MONTERREY, AND THE MANGER TOLD ME THAT HE HAS HAD FIVE ENGINE BAY FIRES IN AEROSTAR MINIVANS IN RECENT MONTHS. IN THE 'GOOD OLD DAYS' UNDERSTAND THERE WAS A FUSIBLE LINK BETWEEN THE ALTERNATOR CHARGING LINE AND THE BATTER
THE ALTERNATOR FAILED SHORT CIRCUIT. MASSIVE AMOUNTS OF CURRENT PASSED FROM THE BATTERY THROUGH THE ALTERNATOR, WHICH BURST INTO FLAMES. THE FAULT CAUSED THE ENGINE TO STALL DUE TO LACK OF IGNITION AND IT WAS EXTREMELY DIFFICULT TO STEER AND STOP THE VEHICLE AS A RESULT OF LOSS OF POWER STEERING AND POWER BRAKES. SMOKE WAS POURING FROM THE FRONT OF THE VEHICLE. WHEN I MANAGED TO STOP AND OPEN THE HOOD, THE ALTERNATOR, WHICH WAS GLOWING RED INSIDE, BURST INTO FLAMES AND SET FIRE TO CABLES AND RUBBER HOSES AROUND IT. I RECEIVED BURNS TO MY HANDS TRYING TO PUT THE FIRE OUT. LUCKY FOR ME ANOTHER MOTORIST STOPPED AND HE HAD AN EXTINGUISHER. I HAVE NOW HAD TWO FIRES OF THIS TYPE, ONE ON EACH OF MY VEHICLES. YESTERDAY I WENT TO AN ALTERNATOR REMANUFACTURING COMPANY HERE IN MONTERREY, AND THE MANGER TOLD ME THAT HE HAS HAD FIVE ENGINE BAY FIRES IN AEROSTAR MINIVANS IN RECENT MONTHS. IN THE 'GOOD OLD DAYS' UNDERSTAND THERE WAS A FUSIBLE LINK BETWEEN THE ALTERNATOR CHARGING LINE AND THE BATTER
Unintended Transmission Downshift and Rear Wheel Lock-up
Timing Belt Failure
Underbody shields detachment
B-Pillar Trim Detachment
Unintended Transmission Downshift and Rear Wheel Lock-up
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.