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1991 Ford Aerostar Problems

Find the most common issues based on 1991 Ford Aerostar owner complaints.
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Most Common 1991 Ford Aerostar Problems

Engine oil leaks are known to develop around the rear crankshaft (main) seal and engine oil pan gasket.
If you experience poor idle quality and fuel economy (and the Check Engine Light illuminates) after the exhaust system or motor has been removed and replaced, it could be that the oxygen sensor wir...
If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing deferential clutch kit. An updated differ...
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1 Known 1991 Ford Aerostar Brakes Problem

The front brakes may stick, bind, or grab. This can happen when the front brake caliper pins become corroded. Cleaning or replacing the caliper pins will be necessary to correct this problem.

1 Known 1991 Ford Aerostar Drive Train Problem

If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing deferential clutch kit. An updated differ...

2 Known 1991 Ford Aerostar Electrical & Lights Problems

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.
For the 2.3L 4 Cylinder and 5.0L V8 engine, the electrical ignition switch poses a fire hazard. An updated switch is available.

4 Known 1991 Ford Aerostar Engine Problems

Engine oil leaks are known to develop around the rear crankshaft (main) seal and engine oil pan gasket.
The valve cover gasket may fail, causing engine oil to leak onto the exhaust manifolds.
An engine knocking noise coming from the lower end during acceleration is common and could be caused by worn or damaged engine bearings.

1 Known 1991 Ford Aerostar Exhaust & Emissions Problem

If you experience poor idle quality and fuel economy (and the Check Engine Light illuminates) after the exhaust system or motor has been removed and replaced, it could be that the oxygen sensor wir...

2 Known 1991 Ford Aerostar Heating & Air Conditioning Problems

The AC system may be performing poorly even if it seems to be functioning properly. This could be caused by the AC air blend door being out of adjustment.
Excessive cycling of the AC compressor clutch when the system is fully charged could be caused by sludge that has built up on the engine throttle body. Throttle body should be cleaned periodically ...

0 Known 1991 Ford Aerostar Maintenance Problems

0 Known 1991 Ford Aerostar Miscellaneous Problems

2 Known 1991 Ford Aerostar Suspension & Steering Problems

While steering, if you hear a clunk or a rattle, or if you experience premature tire wear, this could indicate the inner tie rod ends are loose or worn and will require replacement.
Failure to change the power steering fluid can cause the fluid to become gray with metal particles. The contaminated fluid can damage the power steering pump resulting in a growling noise when the ...

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Known 1991 Ford Aerostar Problems & Complaints

The AC system may be performing poorly even if it seems to be functioning properly. This could be caused by the AC air blend door being out of adjustment.
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.
Engine oil leaks are known to develop around the rear crankshaft (main) seal and engine oil pan gasket.
If you experience poor idle quality and fuel economy (and the Check Engine Light illuminates) after the exhaust system or motor has been removed and replaced, it could be that the oxygen sensor wir...
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.
The front brakes may stick, bind, or grab. This can happen when the front brake caliper pins become corroded. Cleaning or replacing the caliper pins will be necessary to correct this problem.
While steering, if you hear a clunk or a rattle, or if you experience premature tire wear, this could indicate the inner tie rod ends are loose or worn and will require replacement.
Failure to change the power steering fluid can cause the fluid to become gray with metal particles. The contaminated fluid can damage the power steering pump resulting in a growling noise when the ...
Excessive cycling of the AC compressor clutch when the system is fully charged could be caused by sludge that has built up on the engine throttle body. Throttle body should be cleaned periodically ...
For the 2.3L 4 Cylinder and 5.0L V8 engine, the electrical ignition switch poses a fire hazard. An updated switch is available.
The valve cover gasket may fail, causing engine oil to leak onto the exhaust manifolds.
If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing deferential clutch kit. An updated differ...
An engine knocking noise coming from the lower end during acceleration is common and could be caused by worn or damaged engine bearings.
Get a Repair Estimate
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RepairPal estimates are guaranteed at over 1,700 quality certified locations nationwide. Learn more
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