The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.
Ford Aerostar Problem Reports
RepairPal Verified Ford Aerostar Problem Reports
An engine knocking noise coming from the lower end during acceleration is common and could be caused by worn or damaged engine bearings.
For the 2.3L 4 Cylinder and 5.0L V8 engine, the electrical ignition switch poses a fire hazard. An updated switch is available.
Automatic transmission failure is higher than normal in this model. Small metal pieces may be found at the bottom of the transmission oil pan when the transmission is serviced.
The radius arm bushings may wear prematurely due to oil leaking onto the bushings; this causes a loud clunk when the vehicle is shifting gears or stopping.