An engine knocking noise coming from the lower end during acceleration is common and could be caused by worn or damaged engine bearings.
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Repairpal verified Ford Aerostar problems
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.