Ford Aerostar Problems

RepairPal has identified the most common problems with the Ford Aerostar as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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Known Problems

Bad throttle position sensors can cause high idle without causing the Check Engine Light to illuminate.

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 function. A sign of front pump failure can be a whine type noise.

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.

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 wheel is turned; the damaged pump will require replacement to eliminate the noise.. Life of the power steering gearbox and pump will be shortened if the fluid is not serviced regularly.

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 engine is warm.

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

The 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.

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 wires are crossed at the rear of the motor. Wiring schematics should be checked to ensure that the correct harness plug is connected to the corresponding sensor.


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 unless there is a sticker on it stating no cleaning is allowed. Some throttle bodies have a special coating that should not be cleaned.

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