1994 Ford Aerostar: Recalls, Problems & MPG
Here are the deets on the 1994 Ford Aerostar: 3 recalls, 257 owner complaints and up to 19 mpg combined.
Recalls
3 vehicle recalls from the manufacturer, plus 2 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Transmission & drivetrain Vehicle recall #97V204000 · 1997 · 75,000 vehicles
What's wrong: 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.
Why it matters: This condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
The fix: Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
Electrical Vehicle recall #99V028000 · 1999 · 23,097 vehicles
What's wrong: Heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. The vehicle could experience a loss of power and become immobilized and the fuel gauge May be erratic.
Why it matters: Heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. The short circuit could also have the potential for a vehicle fire.
The fix: Dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.
Electrical Vehicle recall #99V029000 · 1999 · 762,201 vehicles
What's wrong: 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.
Why it matters: This can cause over heating and the potential for a vehicle fire.
The fix: Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
2 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Brakes (air) Equipment recall #98E010000 · 1998 · 23,500 vehicles
What's wrong: 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.
Why it matters: Loss of braking can result.
The fix: 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.
Brakes (hydraulic) Equipment recall #06E022000 · 2006 · 7,440 vehicles
What's wrong: 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…
Why it matters: 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.
The fix: 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.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 28 mention a fire, 33 injuries and 4 deaths were reported.
What owners describe
- Electrical (69): the most common themes are electrical failure (30), fire / smoke (20).
- Airbags (44): the most common themes are fails to deploy (13), warning light on (7).
- Transmission & drivetrain (42): the most common themes are leaks (7), stalls / loses power (4), hard / delayed shifting (4).
- Brakes (hydraulic) (23): the most common themes are noise or vibration (5).
The 1994 Ford Aerostar has 257 owner complaints, ranking #3 of 11 Aerostar model years for complaints (1.7× the average Aerostar year). Complaints peaked in 1999 (67 filed that year). The typical problem showed up when the car was about 4 years old, at a median of 109,089 miles. Neighboring years: 1993 (374 complaints, 2 recalls), 1995 (157 complaints, 5 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 3.0 L 6-cyl | Manual 5-spd | Rear-Wheel Drive | 17 | 23 | 19 | Regular |
| 3.0 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 16 | 22 | 18 | Regular |
| 3.0 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 15 | 21 | 17 | Regular |
| 3.0 L 6-cyl | Manual 5-spd | Rear-Wheel Drive | 15 | 22 | 17 | Regular |
| 4.0 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 14 | 19 | 16 | Regular |
| 4.0 L 6-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 14 | 18 | 16 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 1994 Ford Aerostar.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
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FAQ
Does the 1994 Ford Aerostar have any recalls?
Yes. NHTSA lists 3 vehicle recalls for the 1994 Ford Aerostar, plus 2 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 1994 Ford Aerostar problems?
Owners have filed 257 complaints with NHTSA. The most-reported areas are electrical (69), airbags (44), transmission & drivetrain (42).
What gas mileage does the 1994 Ford Aerostar get?
EPA ratings run up to 19 mpg combined (3.0 L, Manual 5-spd), across 6 engine and transmission combos.
Where can I get a 1994 Ford Aerostar repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.