Ford Aerostar Wagon 1993

• Recall 59312 [USA]: Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
  Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. These brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. Only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. When subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.
  affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. The recall began on march 20, 2006. Owners can contact affina group customer service at 1-800-323-0354.
  this recall only pertains to aftermarket napa, raybestos, ac delco, aimco, carquest, and bendix brake hydraulic master cylinders and has no relation to any original equipment installed on daimlerchrysler or ford vehicles.Customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.Safercar.Gov.

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• Recall 9096 [USA]: This can cause over heating and the potential for a vehicle fire.
  Vehicle description: mini vans. These vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.
  dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
  owner notification began march 19, 1999.Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contactford at 1-800-392-3673.Also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).

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• Recall 10924 [USA]: Loss of braking can result.
  Equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.
  aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.
  owner notification is expected to begin during april 1998.Owners who do not receive the free rotors within a reasonable time should contact aimco at 815-759-7935.Also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).

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• Recall 16254 [USA]: This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
  Vehicle description: all wheel drive passenger minivans. These vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. The powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. Fluid explusion, driveshaft separation or loss of vehicle drive can result.
  dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
  owner notification is expected to begin february 16,1998.Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.Also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

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• Recall 2001193 [Canada]: Other
  Certain vehicles, from ontario to newfoundland, could experience a corrosion related failure of the spare tire winch cable. If the cable breaks while the vehicle is being driven, the spare tire could drop down, potentially creating a roadway obstacle. Correction: owners are to inspect the cable, and if corrosion or broken wire strands are present the vehicle is to be taken to a dealer for replacement of the winch assembly. Program ends september 30, 2003.

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• Recall 1999032 [Canada]: Electrical
  On certain vehicles, a short circuit could occur at the a2 accessory terminal in the ignition switch of these vehicles when the switch is in the "on" position causing overheating and the potential for a vehicle fire. Correction: a jumper harness with a relay will be installed which will re-route and activate all a2 accessories through the relay.

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• Recall 1997207 [Canada]: Powertrain
  On certain aerostar awd vehicles, extended operation at speeds of over 130 kph may result in structural failure of the transmission/transfer case assembly. This could result in fluid expulsion, driveshaft separation or loss of vehicle drive. Fluid leakage in the presence of an ignition source could cause a vehicle fire and driveshaft separation may lead to loss of vehicle control. Correction: transfer case extension housing will be replaced and steel driveshaft will be replaced with an aluminum driveshaft.

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To ensure accuracy and for your safety, it is recommended to do a free VIN recall check here or here [USA] - UK - Canada.

Bulletins are notices put out by manufacturers in conjunction with the NHTSA to notify the public of manufacturing issues or changes.

• Luggage compartment door drops abruptly investigation # PE02076

  Odi has identified 30 incidents resulting in minor to moderate personal injuries that have been caused by abrupt door drops over the approximately eight - twelve year period of product usage and exposure (1991-1995 to 2003).Most of the injury incidents appear to have been caused by a fracture of the gas filled lift assist cylinder mounting stud.Stud fractures have occurred randomly over time and do not exhibit any apparent trend relating to date of vehicle production or time-in-service (exposure).The odi closing report summarizes the details of this investigation.
  

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• Transfer cases and rear drive shaft investigation # EA99002

  There is no summary currently available
  

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• Transfer cases and rear driveshaft investigation # RQ98012

  There is no summary currently available
  

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• Fuel sender assembly fires investigation # EA98016

  There is no summary currently available
  

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Tl* the contact owns a 1993 ford aerostar. While driving at approximately 80 mph, there was a vibration coming from the driver side and there was fluid leaking from the vehicle. The contact noticed that the transmission transfer case was fractured and fluid was leaking. The vehicle was towed to the contacts residence. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was not available.

Backed into pine tree in driveway. Shattered plastic bumper cover. Can not replace bumper cover because ford says obsolete. Also no after market bumper can be found for this model. This bumper protects no one. *js ford won't even give me the ford part number. Its a cargo van. Other model covers can be bought from after market sellers but not the cargo van. Only place to get one is junk yards if you are get lucky. Most of their covers are busted also. A car is a hazard without a bumper. *js

Tl* the contact owns a 1993 ford aerostar. The contact stated that the key became lodged in the ignition. The vehicle was not taken to the dealer for a diagnostic testing. The manufacturer was notified of the failure. The vin was not available. The approximate failure mileage was 169,000.

Tl*the contact owns a 1993 ford aerostar. The contact stated that he noticed electrical problems. There was a clicking sound and he could feel a pulsation in the dashboard; there were also electrical shortages. He called the dealership about recall 99v029000 and was told that his vehicle was not included in the recall. He also consulted the manufacturer and it was confirmed that the vehicle was not included. The vehicle had not been repaired to-date. The current mileage was 144,705. The failure mileage was approximately 144,670. Updated 02/22/11

Just got home and was parked in front of the house. About 30 min later someone was knocking on are door telling us the van was on fire. There was no keys left in the van. The fire burn the dash and the right side of the inside of the engine and the hood. The van is now total. *nm

Dt*: the contact stated upon changing both the fuel filter and the oil filter, the vehicle made a knocking noise while driving 20 mph. The vehicle was taken to a private repair shop who was unable to determine the cause of the problem.

Tl*the contact owns a 1993 ford aerostar. The contact stated that his vehicle was produced with a higher than specified electrical load through the accessory power feed circuit. The potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur; therefore, creating a short circuit and allowing current to flow through the ground wire. On numerous occasions, he noticed that the switch module melted and the instrument control panel lighting was inoperative. As a result, the risk of a severe fire increased. The manufacturer stated that the vin was excluded from nhtsa campaign id number 99v029000 (electrical system:ignition:switch); therefore, they would not assume financial responsibility for the repair. The vehicle has not been repaired. The failure mileage was 168,000 and current mileage was 180,000.

Air bag light started flashing constantly, then horn and cruise control stopped working. Noise in column sounds like loose wires flopping.

Brake lights constantly shorting out. I have to replace them 2 or more times per year. I use long-life bulbs, but they continually go out. I see many other aerostar vehicles with similar situation. While this has not caused an accident yet, unless i constantly check the lights, i may be involved in an accident and/or ticket due to this defect. *nm