1986 Ford Aerostar problems
The Ford Aerostar is a range of vans that was manufactured by Ford from the 1986 to the 1997 model years. The first minivan produced by Ford, the model line was marketed against the Chevrolet Astro/GMC Safari and the first two generations of the Chrysler minivans. Introduced shortly before the Ford Taurus, the Aerostar derived its name from its slope-nosed "one-box" exterior (although over six feet tall, the body of the Aerostar retained a drag coefficient of Cd=0.37, besting the Lincoln Mark VII).
The first minivan powered exclusively by V6 engines, the Aerostar was also one of the first vehicles to introduce all-wheel drive to the segment in North America. The model line was sold in multiple configurations, including passenger and cargo vans, along with an extended-length body. Sold primarily in the United States and Canada, a limited number of vehicles were exported outside of North America.
The Aerostar was replaced for the 1995 model year by the front-wheel drive Ford Windstar; Ford sold both model lines concurrently through the 1997 model year. The role of the Aerostar cargo van was left unfilled, with the Ford Transit Connect serving as the closest successor (in terms of size and capability).
For its entire production, the model line was assembled by the St. Louis Assembly Plant in Hazelwood, Missouri. In total, 2,029,577 vehicles were produced across a single generation.
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Common 1986 Ford Aerostar problems
The Ford Aerostar, produced between 1986 and 1997, is known for several common problems, particularly in the 1986-1991 model years. One of the most prevalent issues is transmission problems, with many owners reporting issues such as slipping, hesitation, or complete failure. These issues are often caused by a faulty torque converter or worn-out transmission fluid. Additionally, some owners have experienced hard shifting or failure to shift properly, which can be attributed to worn-out gears or solenoids.
Another common problem area is the engine, with many owners reporting stalling, misfiring, or rough running. These issues can be caused by various factors, including a clogged fuel filter, faulty spark plugs or wires, or a malfunctioning fuel injector. Overheating or loss of power can also occur, which may be due to a faulty water pump or radiator.
The braking system is another frequent source of problems for the Ford Aerostar. Many owners have reported issues such as squeaking, grinding, or failure of the brakes, often due to worn-out brake pads or rotors, or a faulty brake master cylinder. Low or spongy brake pedals can also be a problem, which may be caused by leaks in the brake lines or a malfunctioning brake booster.
Electrical system issues are also common, with owners reporting problems with the battery and alternator, as well as issues with the starter and fuses.
It is worth noting that, despite these common problems, the Ford Aerostar ranks relatively high in reliability compared to other Ford models, with only 3rd place out of 44 models.
In summary, the Ford Aerostar, particularly the 1986-1991 models, is known for several common problems, including transmission issues, engine problems, brake system issues, electrical system issues, and suspension and steering problems. Regular maintenance and inspections can help prevent these issues and extend the life of the vehicle.
What happened to the Ford Aerostar?
The Aerostar was discontinued after 1997 and replaced by the Windstar, which was sold alongside since 1995. although Aerostar's role went unfilled until the 2010 introduction of the Ford Transit Connect van.
What was the last year of the Aerostar?
1997
The Ford Aerostar is a range of vans that was manufactured by Ford from the 1986 to the 1997 model years.
What is the mpg on a 1996 Ford Aerostar XLT?
Based on data from 4 vehicles, 257 fuel-ups and 57,711 miles of driving, the 1996 Ford Aerostar gets a combined Avg MPG of 12.22 with a 0.29 MPG margin of error.
What is the fuel mileage of a 1995 Ford Aerostar?
Fuel Economy
| City | 15 mpg |
|---|---|
| Highway | 22 mpg |
| Combined | 18 mpg |
What happened to the Ford Aerostar?
The Aerostar was discontinued after 1997 and replaced by the Windstar, which was sold alongside since 1995. although Aerostar's role went unfilled until the 2010 introduction of the Ford Transit Connect van.
What was the last year of the Aerostar?
1997
The Ford Aerostar is a range of vans that was manufactured by Ford from the 1986 to the 1997 model years.
What is the fuel mileage of a 1995 Ford Aerostar?
Fuel Economy
| City | 15 mpg |
|---|---|
| Highway | 22 mpg |
| Combined | 18 mpg |
What is the mpg on a 1996 Ford Aerostar XLT?
Based on data from 4 vehicles, 257 fuel-ups and 57,711 miles of driving, the 1996 Ford Aerostar gets a combined Avg MPG of 12.22 with a 0.29 MPG margin of error.
1986 Ford Aerostar car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Ford Aerostar problems, we found that the most common problems with these 2023 model year vehicles are:
- Electrical system problems
- Engine and engine cooling problems
- Power train problems
- Seat belts problems
- Fuel system problems
The graph below shows statistics for all 1986 Ford Aerostar vehicle components and the number of complaints received.
Latest 25 complaints 1986 Ford Aerostar
The NHTSA has received 72 complaints about various vehicle components related to the 1986 Ford Aerostar. Below are the 25 most recent complaints reported for 1986 Ford Aerostar vehicles.
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2016-06-01
- VIN: 1FMCA11U6GZ
- Components: FUEL/PROPULSION SYSTEM
- Summary: THE GROMMET IN THE FUEL TANK IS LEAKING. FUEL IS ESCAPING FROM THE TANK AND MAY CAUSE A FIRE. THERE IS A CONSTANT ESCAPE OF FUEL MOVING OR STATIONARY. THEREFORE THIS SYSTEM WILL NOT PASS SMOG BECAUSE WHEN PRESSURIZED, IT WILL NOT HOLD AIR. THIS IS A CALIFORNIA REQUIREMENT. IT IS ALSO MOST DANGEROUS. FORD MOTOR CO. WILL NOT CORRECT THIS PROBLEM. THE 9 RECALLS FOR THIS MODEL IS ON YOUR SYSTEM.
POWER TRAIN PROBLEM
- Date Of Incident: 2000-10-01
- VIN: ADD
- Components: POWER TRAIN
- Summary: TRANSMISSION WAS REBUILT 3 YEARS AGO AT FORD DEALER, THEN, IN OCT 2000 WHILE DRIVING 55 MPH TRANSMISSION WENT OUT AGAIN. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 2024-11-24
- Fire: 1
- VIN: 1FMCA11U5GZ
- Components: ELECTRICAL SYSTEM
- Summary: TRIED TO START VAN AND FIRE STARTED. *AK
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 1999-09-05
- VIN: 1FMCA11S1GZ
- Components: ENGINE AND ENGINE COOLING
- Summary: POSSIBLE WIRING HARNESS IN THE ENGINE FAILURE RESULTING IN FIRE. NLM
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 1999-09-05
- VIN: 1FMCA11S1GZ
- Components: ENGINE AND ENGINE COOLING
- Summary: POSSIBLE WIRING HARNESS IN THE ENGINE FAILURE RESULTING IN FIRE. NLM
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1999-09-05
- VIN: 1FMCA11S1GZ
- Components: ELECTRICAL SYSTEM
- Summary: POSSIBLE WIRING HARNESS IN THE ENGINE FAILURE RESULTING IN FIRE. NLM
POWER TRAIN PROBLEM
- Date Of Incident: 2024-11-24
- Components: POWER TRAIN
- Summary: WHEN APPLYING GAS THERE IS NO POWER, AS IF VEHICLE IS IN NEUTRAL. DEALER SAYS THE VEHICLE HAS THE WRONG TRANSMISSION IN IT. *AK
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 1999-08-13
- Fire: 1
- Components: ENGINE AND ENGINE COOLING
- Summary: VEHICLE EXPERIENCED ENGINE FIRE, CONSUMER BELIEVES THIS FAILURE IS RELATED TO PAST RECALLS. NLM
SEATS PROBLEM
- Date Of Incident: 1992-12-10
- VIN: 1G8CM15Z0GB
- Components: SEATS
- Summary: DRIVER'S SEAT BROKE DUE TO A FAULTY BOLT IN THE HINGES. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1998-02-01
- VIN: 1FMCA11U7GZ
- Components: ELECTRICAL SYSTEM
- Summary: THIS VAN HAS FAILED ME OVER AND OVER AGAIN AND OUT OF THE 1.5 YEARS OF OWNERSHIP I DROVE IT FOR 2 MONTHS AND NOT EVEN 6000 MILES .IT WAS PUT IN THE SHOP 7 TIMES, AND FINALLY BURNT UNDER THE HOOD AND DOG HOUSING. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1999-05-16
- VIN: 1FMCA11S0GZ
- Components: ELECTRICAL SYSTEM
- Summary: THE FRONT OF STARTER CRACKED UPON STARTING THE VEHICLE. *AK
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 1998-12-27
- VIN: 1FMCA11S0GZ
- Components: FUEL SYSTEM, GASOLINE
- Summary: HAD FILLED VEHICLE WITH GASOLINE. NOTICED THAT THE TANK HAD STARTED TO LEAK AFTERWARDS. TOOK VEHICLE TO DEALER & HAD IT CHECKED. THE MECHANIC NOTICED THE FUEL WAS LEAKING FROM THE TOP OF THE TANK IN & AROUND THE SEAM AREA.*AK
POWER TRAIN PROBLEM
- Date Of Incident: 2024-11-24
- Components: POWER TRAIN
- Summary: TRANSMISION HAS FAILED ON FIVE OCCASIONS.
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 1998-08-17
- VIN: PLEASE FILL
- Components: ENGINE AND ENGINE COOLING
- Summary: CONSUMER EXPERIENCING ENGINE STALLING UPON STARTING THE VEHICLE. AFTER ENGINE WARMS UP, THE VEHICLE WOULD RUN NORMALLY. DEALER WAS NOT NOTIFIED. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1998-02-28
- Fire: 1
- VIN: 1FMCA11U7G2
- Components: ELECTRICAL SYSTEM
- Summary: IGNITION SWITCH FAILED, CAUSING FIRE.
SEAT BELTS PROBLEM
- Date Of Incident: 1996-12-01
- VIN: 1FMCA11U7G2
- Components: SEAT BELTS
- Summary: DRIVER'S SEAT BELT FAILED.
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1997-12-30
- Fire: 1
- VIN: 1FMCA11U7GZ
- Components: ELECTRICAL SYSTEM
- Summary: SMOKE EMMITTED FROM IGNITION SWITCH.
POWER TRAIN PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1FMCA1164GZ
- Components: POWER TRAIN
- Summary: TRANSMISSION NOT WORKING PROPERLY.
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 1997-08-08
- Fire: 1
- VIN: 1FDDA14V1GZ
- Components: ENGINE AND ENGINE COOLING
- Summary: VEHICLE FIRE.
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 2024-11-24
- Fire: 1
- VIN: 1FMCA11U762
- Components: ENGINE AND ENGINE COOLING
- Summary: VEHICLE CAUGHT FIRE FOR NO REASON. THIS WAS THE SECOND FIRE THAT HAS OCCURRED IN ENGINE COMPARTMENT. CAUSE HAS NOT BEEN DETERMINED. *AK
EQUIPMENT PROBLEM
- Date Of Incident: 1997-01-01
- VIN: 1FMCA11U9GZ
- Components: EQUIPMENT
- Summary: THE CABLE WHICH HOLDS THE SPARE TIRE RUSTED, ALLOWING TIRE TO FALL.
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 2024-11-24
- Fire: 1
- Components: ELECTRICAL SYSTEM
- Summary: OWNER STATES WHILE SITTING IN VEHICLE WITH ENGINE IDLING NOTICED SMOKE COMING FROM UNDERNEATH HOOD OF VEHICLE WHICH THEN LED TO A FIRE. *AK
STRUCTURE PROBLEM
- Date Of Incident: 1997-02-05
- Components: STRUCTURE
- Summary: THE PASSENGER'S SIDE PLASTIC DOOR HANDLE IS BROKEN FROM THE OUTSIDE, CONSUMER CANNOT OPEN THE DOOR FROM THE OUTSIDE. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1FNCA11U5GZ
- Components: ELECTRICAL SYSTEM
- Summary: WIRING HARNESS FROM THE ALTERNATOR BURNED OUT . PLEASE DESCRIBE .
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1996-09-28
- Fire: 1
- VIN: 1FMCA11UXGZ
- Components: ELECTRICAL SYSTEM
- Summary: WHILE THE VEHICLE WAS PARKED THERE WAS A FIRE IN THE RIGHT FRONT ENGINE COMPARTMENT. ALSO NOTICED THAT WHEN KEY IS IN IGNITION THE SWITCH GETS HOT.*AK
1986 Ford Aerostar recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 9 recalls for different components of the 1986 Ford Aerostar.
- Manufacturer: FEDERAL-MOGUL CORPORATION
- Components: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
- Summary: CERTAIN FEDERAL-MOGUL AFTERMARKET FUEL PUMPS SOLD UNDER THE BRAND NAMES OF CARTER, ACCUFLOW, NAPA, TRUFLOW, PARTS DEPO, AND PARTS MASTER, SHIPPED BETWEEN AUGUST 2006 AND JULY 2007 FOR USE ON THE VEHICLES LISTED ABOVE. THE FUEL PUMP DIAPHRAGM IN CERTAIN PRODUCTION RUNS MAY HAVE BEEN IMPROPERLY INSTALLED OR INADEQUATELY TESTED WHICH MAY CAUSE THE FUEL PUMP TO LEAK.
- Consequence: A LEAKING FUEL PUMP COULD CREATE A VEHICLE FIRE HAZARD.
- Remedy: FEDERAL-MOGUL WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 15, 2007. OWNERS CAN CONTACT FEDERAL-MOGUL AT 248-354-7700.
- Manufacturer: AIMCO PRODUCTS INC.
- Components: SERVICE BRAKES, AIR:DISC:ROTOR
- Summary: 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.
- Manufacturer: FORD MOTOR COMPANY
- Components: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
- Summary: INSUFFICIENT INTERFERENCE FIT BETWEEN FUEL TANK FILLER PIPE AND GROMMET COULD RESULT IN AN INADEQUATE SEAL WHICH COULD ALLOW FUEL TO SEEP FROM THE JOINT.
- Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, FUEL LEAKAGE COULD RESULT IN A FIRE.
- Remedy: INSTALL A REVISED DESIGN GROMMET.
- Manufacturer: FORD MOTOR COMPANY
- Components: SEAT BELTS:FRONT:ANCHORAGE
- Summary: VANS WERE PRODUCED WITHOUT PLASTIC COVER DESIGNED TO COVER OUTBOARD SEAT BACK PIVOT HINGE ALLOWING WEBBING OF FRONT PASSENGER-SIDE SAFETY BELTS TO BECOME ABRADED OR CUT DUE TO CONTACT WITH EXPOSED HINGE.
- Consequence: DAMAGE TO BELT WEBBING COULD WEAKEN BELTS TO POINT OFFAILURE INCREASING RISK OF INJURY IN AN ACCIDENT OR A SUDDEN STOP.
- Remedy: INSTALL PLASTIC PIVOT COVER; REPLACE BELTS AS NECESSARY.
- Manufacturer: FORD MOTOR COMPANY
- Components: SEATS
- Summary: WIRING FOR THE POWER LUMBAR SEAT SYSTEM WAS ROUTED DIRECTLY BENEATH THE SEAT CUSHION SPRINGS AND MAY BE ABRADED BY THE SPRINGS.
- Consequence: THIS COULD RESULT IN A SHORT CIRCUIT WHICH MAY CREATESUFFICIENT HEAT TO START A FIRE IN THE SEAT CUSHION PAD AND/OR TRIM COVER.
- Remedy: INSTALL A FUSE WITHIN THE POWER LUMBAR ELECTRICAL CIRCUIT.
- Manufacturer: FORD MOTOR COMPANY
- Components: ELECTRICAL SYSTEM:WIRING
- Summary: VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE HAVE A TRAILER TAILLIGHT RELAY ASSEMBLY THAT CONTAINS WIRES OF SMALLER GAUGE THAN THE FUSE LINK WHICH PROTECTS THE CIRCUIT.
- Consequence: SHOULD A SHORT CIRCUIT OCCUR IN THE WIRING WITHIN THERELAY OR IF WATER INTRUSION OCCURS THE SMALLER GAUGE WIRE IN THE RELAY WILLFUNCTION AS A FUSE LINK AND OVERHEAT. THE POSSIBILITY EXISTS FOR A FIRE IF THEWIRES ARE EXPOSED TO COMBUSTIBLE MATERIALS.
- Remedy: INSTALLATION OF A RELAY WITH WIRES OF GAUGE ADEQUATE TO PROTECT THE CIRCUIT.
- Manufacturer: FORD MOTOR COMPANY
- Components: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
- Summary: SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.
- Consequence: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.
- Remedy: INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.
- Manufacturer: FORD MOTOR COMPANY
- Components: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
- Summary: FUEL TANKS MAY HAVE BEEN SCORED OR PENETRATED WHEN FLOOR PAN MOUNTING HOLES FOR THE PARTITIONS WERE DRILLED. CONSEQUENCE OF DEFECT: FUEL LEAKAGE MAY OCCUR AND IN THE PRESENCE OF AN IGNITION SOURCE, THE POTENTIAL FOR A FIRE WOULD EXIST.
- Remedy: REPLACE FUEL TANKS AS NECESSARY.
- Manufacturer: FORD MOTOR COMPANY
- Components: SUSPENSION:REAR:SPRINGS:LEAF SPRING ASSEMBLY
- Summary: THERE MAY BE INADEQUATE WELDING IN SOME UNDERBODY STRUCTURAL AREAS, INCLUDING THOSE AT THE REAR SUSPENSION ATTACHMENTS, WHICH MAY CAUSE IT TO SEPARATE. CONSEQUENCE OF DEFECT: IF REAR SUSPENSION ATTACHMENTS SHOULD SEPARATE FROM THE UNDERBODY DURING VEHICLE USE, THE AXLE COULD SHIFT DURING ACCELERATION OR BRAKING AND MAY ADVERSELY AFFECT THE STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT.
- Remedy: REINFORCE SUSPECT WELD LOCATIONS AND MODIFY TO PREVENT WELD FAILURE.
Additional sources
More sources of information about 1986 Ford Aerostar problems:
Ford Aerostar Transmission: Expert Q&A on Fluid Issues | JustAnswer
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Ford Aerostar 1995: Expert Q&A on Idle Problems & Rough Idling
Jun 23, 2008 ... I have a 1995 Aerostar with idle problems. it idles rough at redlights. Any common idle problems you could throw at me to elp get me started?
Solved - My 1995 Ford Aerostar won't start. | Ford Explorer Forums ...
Feb 5, 2013 ... ... Ford Aerostar. February 6, 2013 · #5. 95 Aerostar problems ... common then the 4.0 When I searched for the ... 1,986. December 25, 2013.
Why did the Ford Windstar/Freestar flop so hard compared to the ...
Nov 13, 2023 ... ... common anymore. Upvote 3. Downvote ... Not really, the Ford Aerostar mini-van was released in 1986 ... engine bay just exacerbated this issue. The ...
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