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Ford Aerostar Problems

Find the most common issues based on Ford Aerostar owner complaints.
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Most Common 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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3 Known Ford Aerostar Brakes Problems

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.
3.0LThe front brake pads tend to wear faster than normal. Brake rotors have directional vents and are often installed on the wrong side.
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.

3 Known Ford Aerostar Drive Train Problems

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...
Transmission problems are common in this model, often as a result of a failed front pump. The pump loses its ability to create hydraulic pressure, which an automatic transmission needs to functio...
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.

2 Known 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.

7 Known 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.

2 Known Ford Aerostar Exhaust & Emissions Problems

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

2 Known 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 Ford Aerostar Maintenance Problems

0 Known Ford Aerostar Miscellaneous Problems

3 Known Ford Aerostar Suspension & Steering Problems

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 ...
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.
4.0LThe 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.

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Known 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.
Bad throttle position sensors can cause high idle without causing the Check Engine Light to illuminate.
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...
Transmission problems are common in this model, often as a result of a failed front pump. The pump loses its ability to create hydraulic pressure, which an automatic transmission needs to functio...
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 ...
The synchronizer shaft for the camshaft position sensor can cause a loud squeak or chirping noise due to failure of the upper bushing. The noise may be erratic and is usually present when the engi...
Vacuum hose damage is common due to engine oil contamination or a plugged PCV valve.
3.0LThe front brake pads tend to wear faster than normal. Brake rotors have directional vents and are often installed on the wrong side.
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.
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 ...
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RepairPal estimates are guaranteed at over 1,700 quality certified locations nationwide. Learn more
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