FORD AEROSTAR · model year

1992 FORD AEROSTAR

439 NHTSA complaints, 38 crash reports for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 1992FORDAEROSTAR carries 439 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 38 crashes, 42 fires, 152 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 1992 AEROSTAR is power train:automatic transmission with 34 filings, followed by electrical system:ignition:switch (34) and power train:automatic transmission:lever and linkage:column shift (21). 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 1992 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.

439
Complaints
38
Crashes
42
Fires
152
Injuries
4
Deaths

Total Complaints

439 filings

Crashes Reported

38 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

Above median complaint volume — review patterns below.

Complaints by Component

ComponentCount
POWER TRAIN:AUTOMATIC TRANSMISSION34
ELECTRICAL SYSTEM:IGNITION:SWITCH34
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT21
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP19
AIR BAGS:FRONTAL15
ENGINE AND ENGINE COOLING:ENGINE14
EQUIPMENT:APPLIANCE:AIR CONDITIONER14
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS13
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS10
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE10
AIR BAGS10
POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)10
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR9
VEHICLE SPEED CONTROL8
ELECTRICAL SYSTEM:IGNITION7

Recent Complaints

20080906SEAT BELTS

SEATBELT DONT WORK. *TR

20080825LATCHES/LOCKS/LINKAGES

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED THE HOLES AND THE VEHICLE WAS FINE. THE MIDAS MECHANIC STATED THAT THE DEALER NEVER SEALED THE HOLES ON THE MUFFLER AND IT NEEDED TO BE REPLACED COMPLETELY. HE ALSO STATED THAT THE FUMES COULD IN FACT GET INSIDE THE PASSENGER COMPARTMENT. ALSO, THE HORN HAS NEVER WORKED ON THE VEHICLE SINCE IT WAS PURCHASED; THEREFORE, THE DEALER CONSTRUCTED THEIR OWN HORN TO CORRECT THE FAILURE. THE SLIDING DOOR ON THE VEHICLE WOULD NOT OPEN AND THE VEHICLE WOULD NOT UNLOCK FROM THE PASSENGER COMPARTMENT. IN ADDITION, THE REAR LIFTGATE FELL ON THE CONTACT'S HEAD SEVERAL TIMES. THE FAILURE MILEAGE WAS UNKNOWN.

20080825ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED THE HOLES AND THE VEHICLE WAS FINE. THE MIDAS MECHANIC STATED THAT THE DEALER NEVER SEALED THE HOLES ON THE MUFFLER AND IT NEEDED TO BE REPLACED COMPLETELY. HE ALSO STATED THAT THE FUMES COULD IN FACT GET INSIDE THE PASSENGER COMPARTMENT. ALSO, THE HORN HAS NEVER WORKED ON THE VEHICLE SINCE IT WAS PURCHASED; THEREFORE, THE DEALER CONSTRUCTED THEIR OWN HORN TO CORRECT THE FAILURE. THE SLIDING DOOR ON THE VEHICLE WOULD NOT OPEN AND THE VEHICLE WOULD NOT UNLOCK FROM THE PASSENGER COMPARTMENT. IN ADDITION, THE REAR LIFTGATE FELL ON THE CONTACT'S HEAD SEVERAL TIMES. THE FAILURE MILEAGE WAS UNKNOWN.

20080825STRUCTURE

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED THE HOLES AND THE VEHICLE WAS FINE. THE MIDAS MECHANIC STATED THAT THE DEALER NEVER SEALED THE HOLES ON THE MUFFLER AND IT NEEDED TO BE REPLACED COMPLETELY. HE ALSO STATED THAT THE FUMES COULD IN FACT GET INSIDE THE PASSENGER COMPARTMENT. ALSO, THE HORN HAS NEVER WORKED ON THE VEHICLE SINCE IT WAS PURCHASED; THEREFORE, THE DEALER CONSTRUCTED THEIR OWN HORN TO CORRECT THE FAILURE. THE SLIDING DOOR ON THE VEHICLE WOULD NOT OPEN AND THE VEHICLE WOULD NOT UNLOCK FROM THE PASSENGER COMPARTMENT. IN ADDITION, THE REAR LIFTGATE FELL ON THE CONTACT'S HEAD SEVERAL TIMES. THE FAILURE MILEAGE WAS UNKNOWN.

20080825ELECTRICAL SYSTEM:HORN

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED THE HOLES AND THE VEHICLE WAS FINE. THE MIDAS MECHANIC STATED THAT THE DEALER NEVER SEALED THE HOLES ON THE MUFFLER AND IT NEEDED TO BE REPLACED COMPLETELY. HE ALSO STATED THAT THE FUMES COULD IN FACT GET INSIDE THE PASSENGER COMPARTMENT. ALSO, THE HORN HAS NEVER WORKED ON THE VEHICLE SINCE IT WAS PURCHASED; THEREFORE, THE DEALER CONSTRUCTED THEIR OWN HORN TO CORRECT THE FAILURE. THE SLIDING DOOR ON THE VEHICLE WOULD NOT OPEN AND THE VEHICLE WOULD NOT UNLOCK FROM THE PASSENGER COMPARTMENT. IN ADDITION, THE REAR LIFTGATE FELL ON THE CONTACT'S HEAD SEVERAL TIMES. THE FAILURE MILEAGE WAS UNKNOWN.

20070813FireVEHICLE SPEED CONTROL:CRUISE CONTROL

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE CRUISE CONTROLS SHUTS ON AND OFF WITHOUT WARNING. SEVERAL YEARS AGO, HE WITNESSED BILLOWS OF SMOKE COMING FROM THE VEHICLE. THE VEHICLE HAS NOT BEEN INSPECTED OR REPAIRED. THE SPEED AND POWERTRAIN WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 145,681.

Mileage: 145,681

20070713ELECTRICAL SYSTEM:WIRING

TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE GROUND WIRES ARE SHORTING OUT THE BRAKE LIGHTS AND OTHER WIRES UNDERNEATH THE DASHBOARD. HE ALSO STATED THAT HIS WINDOWS ARE NOT WORKING. FORD STATED THAT NOTHING COULD BE DONE BECAUSE HIS VIN WAS NOT INCLUDED IN THE RECALL. THE CONTACT STATED THAT HE HAS BEEN BURNED BY THE FAILED WIRES. THE RECALL # WAS UNKNOWN. THE CURRENT MILEAGE IS 171,000 AND FAILURE MILEAGE WAS 150,000.

Mileage: 150,000

20060719EXTERIOR LIGHTING:HEADLIGHTS

DT*: THE CONTACT STATED THAT THE VEHICLE'S HORIZONTAL AND VERTICAL HEADLIGHT ADJUSTERS FRACTURED ON 07/04/06. THE VEHICLE WAS TAKEN TO THE DEALER ON 07/05/06 WHO DETERMINED THAT THERE WAS NO REPLACEMENT PART AVAILABLE TO REPAIR THE PROBLEM. THE TENSION SPRING THAT ASSISTS IN THE PROPER FUNCTIONING OF THE HEADLIGHT ADJUSTERS WAS NO LONGER AVAILABLE AS WELL. THE MANUFACTURER WAS NOT ALERTED. UPDATED 8/1/2006 - *NM

Mileage: 171,900

20060320POWER TRAIN:MANUAL TRANSMISSION

DT*: THE CONTACT STATED WHEN THE VEHICLE WAS PLACED IN DRIVE, IT FAILED TO MOVE FORWARD. THE VEHICLE CURRENTLY ONLY OPERATES IN REVERSE. THE VEHICLE WAS SEEN BY A LOCAL MECHANIC WHO DETERMINED THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION HAD GONE OUT PREVIOUSLY AND WAS REPLACED BY A LOCAL MECHANIC.

Mileage: 194,000

20050121CrashSERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

OWNER WAS GOING AT APPROXIMATELY 45 MPH. OWNER APPLIED THE BRAKES AND THE BRAKES WENT TO THE FLOOR. OWNER SAYS THAT THE FRONT RIGHT BRAKE HOSE LINE POPPED RIGHT OFF. CAUSING THE VEHICLE TO LOSE ALL BRAKE PRESSURE PREVENTING THE VEHICLE FROM STOPPING. PROVIDE FURTHER DETAILS. *NM

Mileage: 68,000

20040913CrashTIRES:TREAD/BELT

DRIVER'S SIDE REAR TIRE EXPERIENCED A TREAD SEPARATION WHILE DRIVING 60-65 MPH, WITH TWO ADULTS AND ONE CHILD IN A FORD AEROSTAR 1992 VAN. THE TIRE REMAINED INFLATED. AFTERMARKET EQUIPMENT, INSTALLED AT 136,671 MILES, TIRE SIZE P215/70R14, DOT# DBHYC2423000. *AK *NM

Mileage: 186,424

20040523SEATS:FRONT ASSEMBLY:RECLINER

SEAT BACK BOLTS SHEARED FOR UNKNOWN REASONS. BOUGHT USED. BUT, NO REPORTED OF PREVIOUS ACCIDENTS. WE HAD NOTICED SOME 'LOOSENESS' IN THE SEAT BACK. BUT, ATTRIBUTED IT TO WEAR IN THE LATCH POSITIONING DEVICE. WHEN THE LAST BOLT SHEARED THE SEAT BACK GAVE WAY DROPPING THE DRIVER TO A RECLINING POSITION. *AK

Mileage: 236,000

20040415POWER TRAIN

CONSUMER DENIED REIMBURSEMENT FOR EXPENSES INCURRED PRIOR TO RECEIVING RECALL. *PH RECALL IS IN REGARDS ON POWER TRAIN MODIFICATION. *LA

20031108TIRES:TREAD/BELT

MASTERCRAFT A/S IV P215/75R14 TIRE FAILED ON RIGHT REAR WHILE TRAVELLING BETWEEN 65-70 MPH ON INTERSTATE. TREAD SEPARATED FROM TIRE WHILE TIRE REMAINED INFLATED. TREAD CAUSED DAMAGE TO INTERIOR OF WHEEL WELL AND EXHAUST PIPE.*AK THIS WAS THE SECOND INCIDENCE ON THIS VEHICLE FOR THE SAME BRAND & MODEL TIRE AS THERE WAS A PREVIOUS FAILURE OF THE SAME TYPE SEVERAL YEARS AGO WITH SAME MODEL TIRE. PLEASE NOTE THAT UNDER TIRES YOUR WEB SITE DOES NOT ALLOW ME TO CHOOSE THE CORRECT SIZE AS THERE ARE ONLY TWO CHOICES.

Mileage: 269,709

20030903POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

THE SHIFTING LEVER IN THE STEERING COLUMN MALFUNCTIONED, WHICH CAUSED THE VEHICLE NOT TO SHIFT. PART# 2F0DC-7215 53. *AK THIS WAS DUE TO A MECHANICAL FAILURE AND MAY BE A MANUFACTURER DEFECT. THE PROBLEM WAS THE TRANSMISSION/SHIFT ACTUATING TUBE. *SCC *JB

Mileage: 142,297

20030805ENGINE AND ENGINE COOLING:ENGINE

CONSUMER STATES THAT WHILE DRIVING AT ANY SPEED AND WITH NO WARNING EHICLE WILL SHUT OFF, CAUSING CONSUMER TO PULL OVER, AND IT WILL BE HARD TO GET THE VEHICLE BACK STARTED.DEALER NOTIFIED.*AK

20030611TIRES

CONSUMER COMPLAINED ABOUT TIRES.*AK

Mileage: 12,000

20030410EXTERIOR LIGHTING:HEADLIGHTS

THE HEAD LIGHTS FLICKERED AND THEN WENT OUT, THE ALTERNATOR WAS REPLACED, HOWEVER THE PROBLEM CONTINUED. *JB

20030318EXTERIOR LIGHTING:HEADLIGHTS

FIRST STARTED OUT A COUPLE OF MONTHS AGO. HEADLIGHTS WOULD FLICKER OFF AND THEN BACK ON. I FIGURED IT WAS NOTHING. NOW THE HEADLIGHTS FLICKER EVERY 30-60 SECONDS, CAN NOT DRIVE VEHICLE AT NIGHT, HAVE ALREADY BEEN PULLED OVER BY POLICE BECAUSE OF IT. I EXPLAINED TO THE OFFICER THERE MUST BE A PROBLEM WITH THE HEADLIGHTS. *JB

Mileage: 142,000

20021115EXTERIOR LIGHTING:HEADLIGHTS

WHILE DRIVING AT HIGHWAY SPEEDS AT NIGHT, HEADLIGHT SWITCH (F49Z-11654-A), WITH AUTOLAMP OPTION, FAILED AND HEADLIGHTS STARTED FLASHING OFF AND ON THEN GOING OUT COMPLETELY. THIS HAS OCCURRED THREE TIMES, 9/98 AT 93,000 MILES (SWITCH REPLACED), 8/01 AT 145,000 MILES (NEW SWITCH AND BLOCK INSTALLED W/OLD WIRING) AND 10/02 AT 160,000 MILES (NEW SWITCH AND BLOCK W/NEW WIRING INSTALLED). VEHICLE NORMALLY DRIVEN WITH HEADLIGHTS ON FOR SAFETY SO USEAGE TIME ON SWITCH IS EXTENSIVE. EACH TIME LIGHTS WENT OUT, THE HEADLIGHT SWITCH CONTACTS, TERMINALS AND WIRE TERMINAL CONNECTORS HAD OVERHEATED AND DISCOLORED. THE OVERHEATING MELTED AND DISTORTED THE PLASTIC SWITCH CASE AND TERMINAL BLOCK (D3TZ-11A648-A), ALLOWING OR FORCING TERMINALS TO DISTORT OR MOVE. BOTH OF THE BATTERY POWER TO MAIN LIGHT SWITCH TERMINALS, A & B AND THE MAIN LIGHT SWITCH TO DIMMER SWITCH TERMINAL, WERE THE ONLY ONES OVERHEATED. DT

Compare 1992FORDAEROSTAR to Similar Vehicles

NHTSA Investigations 8 Open

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Frequently Asked Questions

How many complaints does the 1992 FORD AEROSTAR have?
The 1992 FORD AEROSTAR has 439 NHTSA complaints, 38 crashes, 42 fires, 152 injuries, and 4 deaths reported.
What are the most common problems with the 1992 FORD AEROSTAR?
The most-complained component for the 1992 FORD AEROSTAR is POWER TRAIN:AUTOMATIC TRANSMISSION with 34 complaints. Other frequently reported areas include ELECTRICAL SYSTEM:IGNITION:SWITCH and POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT.
Is the 1992 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.