Ford Aerostar Problem Reports

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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.

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

Ignition module failure is common and causes a "No start" condition or intermittent stalls.

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.

Vacuum hose damage is common due to engine oil contamination or a plugged PCV valve.

The front brake pads may wear faster than normal. The 4x4 hubs will need to be removed on 4WD models to service the front rotors.

4.0L
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.
MAP (manifold absolute pressure) sensor failure is common and the MAP sensor hose to the intake port commonly plugs up or breaks, which can cause unstable idle conditions.