Total Complaints
282 filings
FORD AEROSTAR · model year
1991 FORD AEROSTAR
282 NHTSA complaints, 28 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1991FORDAEROSTAR carries 282 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 28 crashes, 78 fires, 31 injuries, and 1 fatality. 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 1991 AEROSTAR is electrical system:ignition:switch with 32 filings, followed by power train:automatic transmission (21) and power train:automatic transmission:park/neutral start interlock switch (18). 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 1991 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.
282
Complaints
28
Crashes
78
Fires
31
Injuries
1
Deaths
Crashes Reported
28 reports
Source
NHTSA ODI
Federal complaints database
Complaints vs. fleet median (215)
Above median complaint volume — review patterns below.
Complaints by Component
| Component | Count |
|---|---|
| ELECTRICAL SYSTEM:IGNITION:SWITCH | 32 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 21 |
| POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH | 18 |
| VEHICLE SPEED CONTROL | 18 |
| ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD | 12 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP | 12 |
| ELECTRICAL SYSTEM:IGNITION | 12 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER | 11 |
| EQUIPMENT:APPLIANCE:AIR CONDITIONER | 9 |
| ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 8 |
| ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH | 7 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS | 6 |
| STRUCTURE:BODY:DOOR | 6 |
| POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT | 6 |
| LATCHES/LOCKS/LINKAGES:HATCHBACK/LIFTGATE:LOCK | 5 |
Recent Complaints
20170611ELECTRICAL SYSTEM
I HAD MY STARTER REPLACED BREAKS AND RELAY AND IT STILL HAVING PROBLEMS WITH THE ELECTRICAL SYSTEM I CANNOT EVEN TURN ON MY HEADLIGHTS
20060223UNKNOWN OR OTHER
CONSUMER REQUESTING RECALL INFORMATION ON 1991 AEROSTAR RECALL. *TS *NM
20050516FireELECTRICAL SYSTEM:IGNITION:SWITCH
I OWNED A 1991 FORD AEROSTAR WHICH BURST INTO FLAMES AND WAS DESTROYED. I HAVE BEEN BOUNCED AROUND TRYING TO GET SATISFACTIONS BUT SINCE THERE WAS AN ONGOING CLASS ACTION LAW SUIT HAVE NOT RECEIVED ANY COMPENSATION. THE CONSUMERS WIFE NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER, RAN TO CALL THE FIRE DEPARTMENT, BUT BY THE TIME HE RETURNED THE VEHICLE WAS FULLY ENGULFED IN FLAMES. UPDATED 04/14/10.*JB
20040806SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
THE FRONT BRAKE ROTORS WARPED, CAUSING THE VEHICLE TO SHIMMY. DEALERSHIP REPAIRED THE PROBLEM TWICE, BUT THE CONSUMER WAS STILL HAVING THE SAME PROBLEMS. *AK
Mileage: 150,000
20040517FirePOWER TRAIN:AUTOMATIC TRANSMISSION
WHILE DRIVING 65 MPH ANOTHER MOTORIST YELLED AT THE CONSUMER THAT THE VAN WAS ON FIRE. THE FIRE APPEARED TO BE COMING FORM THE MIDDLE TO THE REAR. CONSUMER PULLED OVER, AND NOTICED TRANSMISSION FLUID ON THE UNDERSIDE OF THE VAN. CONSUMER SHUT THE ENGINE OFF, AND FIRE WENT OUT. A TECHNICIAN EXAMINED THE VAN AND STATED THAT THE TRANSFER CASE NEEDED TO BE REPLACED. NHTSA RECALL CAMPAIGN 99V094000 WAS ISSUED. *AK
20040422SERVICE BRAKES, HYDRAULIC
BRAKES OVERHEAT ON A CURVEY ROAD
20040422FUEL SYSTEM, GASOLINE
BRAKES OVERHEAT ON A CURVEY ROAD
20040422UNKNOWN OR OTHER
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
20040422POWER TRAIN
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
20040422ENGINE AND ENGINE COOLING
1) REPLACED BOTH HEAD GASKETS AND BOLTS! 2) REPLACED EXTENSION HOUSING GASKET 3) REPLACED BOTH VALVE COVER GASKETS, OIL PAN GASKET, OIL FILTER ADAPTER O-RINGS
20040422UNKNOWN OR OTHER
TRANSMISSION FLUID ENTERING COOLANT
Mileage: 105,410
20021002STRUCTURE:BODY:DOOR
PASSENGER SIDE SLIDING DOOR WILL NO LONGER OPEN. VEHICLE HAS NOT BEEN EXAMINED BY DEALER. NLM
20020725FireSERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM
CONSUMER STATES THAT WHILE DRIVING DOWN HIGHWAY THE REAR BRAKES LOCKED AND CAUSED A FIRE WHICH MELTED THE REAR TIRES. CONSUMER WAS TRAVELLING APPROX 65MPH WHEN THE VEHICLE BEGAN TO SLOW DOWN AND SMOKE BEGAN COMING FROM THE REAR OF VEHICLE.*JB.
20020701EQUIPMENT:APPLIANCE:AIR CONDITIONER
I WENT TO FIRESTONE IN ST. JOE, MO AND HAD MY AIR CONDITIONING RECHARGED AFTER 9 YEARS OF DRIVING MY VAN. THEY TOLD ME THAT I NEEDED TO REPLACE A HOSE ON THE FRONT OF THE VECHICAL AND THAT THEY NEEDED TO THEN ADD FREON TO THE SYSTEM. THAT WAS IN JULY 19, 2001. IT DIDN'T SEEM AS COLD AS IT HAD BEFORE BUT IT WAS OK. THEN WHEN I NEEDED THE AIR THIS SUMMER I HAD NONE. THEY SAID THAT THE HOSE THAT THEY INSTALLED THEY LATTER WERE TOLD WOULDN'T HOLD THE PRESSURE (I THINK) BUT THAT NOW SENCE IT WAS OVER 6 MONTHS THEY WOULDN'T OR COULDN'T DO ANYTHING. IT COST ME $304.07. THEY SAY THAT YOU PEOPLE KNEW ABOUT THIS PROBLEM. WHAT THE HELL IS GOING ON?*AK
20020611VEHICLE SPEED CONTROL
AS SOON AS CONSUMER SHIFTED TO DRIVE, VEHICLE ACCELERATED ON ITS OWN, WITH TIRES SPINNING. CONSUMER APPLIED BRAKES, THEN PARK BRAKE, AND SHIFTED TO NEUTRAL. CONSUMER ACCIDENTLY SHIFTED TO REVERSE AND HEARD A LOUD CLUNKING SOUND, VEHICLE CAME TO A STOP.*AK *JB
20020603CrashPOWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE. *AK
20020603CrashPOWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH
12 YEAR OLD LISTENING TO RADIO MOVED SHIFTER FROM PASSENGER SIDE. VAN MOVED CAUSING EXTENSIVE LEG INJURY TO A PERSON WHO WAS SITTING BEHIND VEHICLE. *AK
20020109EXTERIOR LIGHTING:HEADLIGHTS:SWITCH
I HAVE BEEN DRIVING AT NIGHT ON SEVERAL DIFFERENT OCCASIONS AND HAD THE HEADLIGHTS SUDDENLY GO OUT ON ME. THE SWITCH FOR THE LIGHTS SEEMS TO BE WARM AT THESE TIMES. THE HEATER SEEMS TO CAUSE THE SWITCH TO HEAT UP AND WHEN IT GETS HOT THE LIGHTS GO OFF. IT MAY CAUSE AN ACCIDENT ONE OF THESE TIMES IF IT ISN'T FIXED. I'M NOT SURE IF REPLACING THE SWITCH WILL HELP OR IF IT WILL HAPPEN EVEN WITH A NEW SWITCH BEACUSE OF THE HEAT PROBLEM. MAYBE THE DESIGN OF WHERE THE SWITCH IS IS BAD. PLEASE ADVISE ME ON WHAT TO DO. THANK YOU.*AK
20011207SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSION REFUSES TO SHIFT INTO REVERSE OR FORWARD AT TIMES. THE CONSUMER STATED THAT THE TRANSMISSION WAS REBUILT AT 68,000 BY THE DEALER AND WITHIN A FEW MONTHS THE SAME PROBLEMS STARTED UP AGAIN. *YH
20011207POWER TRAIN:AUTOMATIC TRANSMISSION
IN DAMP OR WET CONDITIONS REAR BRAKES WILL LOCK UP. TAKEN TO DEALER NUMEROUS TIMES, INSISTED THAT THIS WAS NORMAL FOR THIS VEHICLE. *AK THE TRANSMISSION WILL NOT SHIFT CORRECTLY. UP OR DOWN SHIFTS BETWEEN FIRST AND SECOND GEARS IS VERY ROUGH AND SLOPPY. ALSO, WHEN THE WEATHER IS COLD THE TRANSMISSION REFUSES TO SHIFT INTO REVERSE OR FORWARD AT TIMES. THE CONSUMER STATED THAT THE TRANSMISSION WAS REBUILT AT 68,000 BY THE DEALER AND WITHIN A FEW MONTHS THE SAME PROBLEMS STARTED UP AGAIN. *YH
Compare 1991FORDAEROSTAR to Similar Vehicles
NHTSA Investigations 8 Open
EA26001Engineering AnalysisOpen
Unintended Transmission Downshift and Rear Wheel Lock-up
PE25020Preliminary EvaluationOpen
Timing Belt Failure
DP25001Defect PetitionOpen
Underbody shields detachment
PE25007Preliminary EvaluationOpen
B-Pillar Trim Detachment
PE25002Preliminary EvaluationClosed
Unintended Transmission Downshift and Rear Wheel Lock-up
Frequently Asked Questions
How many complaints does the 1991 FORD AEROSTAR have?▼
The 1991 FORD AEROSTAR has 282 NHTSA complaints, 28 crashes, 78 fires, 31 injuries, and 1 deaths reported.
What are the most common problems with the 1991 FORD AEROSTAR?▼
The most-complained component for the 1991 FORD AEROSTAR is ELECTRICAL SYSTEM:IGNITION:SWITCH with 32 complaints. Other frequently reported areas include POWER TRAIN:AUTOMATIC TRANSMISSION and POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH.
Is the 1991 FORD AEROSTAR safe to buy?▼
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?▼
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.
Vehicle Safety Guides
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.