Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1995 Ford Aerostar owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 1995 Ford Aerostar. While driving 20 MPH, the vehicle shut off without warning. The contact opened the hood and noticed that the fuel lines were extremely hot before they burst into flames. The contact sustained a burned right hand. The fire department stated that the fuel pump caused the fire. A police report was filed. The manufacturer stated that his VIN was not included in NHTSA campaign id number 99V028000 (electrical system: wiring: front under hood). The current and failure mileages were 150,000.
Dt: the caller said ignition failed. She said a year ago that the vehicle started by itself without a key. She stated that currently she had intermittent trouble starting the vehicle. The lights on the dashboard will come on but the vehicle will not start. Dealer said vehicle was not recalled. They will not help her for free. Manufacturer has not been contacted yet.
Upon starting of vehicle in parking lot, a burning smell and then smoke came out of the driver side door. Immediately turned vehicle off and exited. Vehicle towed to dealership. Previously incidents have been reported to NHTSA on 2 other occasions, but still no recall. Ford has assumed no responsibility for this!
Started vehicle, noticed the ignition switch was sluggish - sticking upon starting vehicle. Approx. 5 seconds later vehicle steering column and dash began to smoke intensely, filling vehicle with smoke within 10 seconds. Jumped from vehicle and put out under dash fire with cup of coffee. Frightened children badly.
While driving, the driver's side door panel began smoking and then caught fire without warning. The consumer put out the flames, but the panel kept smoking. The ground wire to the power windows had to be cut to stop the panel from smoking. The burned switch assembly was repaired on the left side door.
When attempting to start vehicle key was placed in the ignition switch and vehicle caught on fire under the dash area of the vehicle,. Also smoke filled the passenger's compartment. Also consumer has lost some electrical functions. Consumer has yet to contact the dealer. Please provide any futher details.
While driving aprroximately 55mph. Started to smell smoke inside of vehicle. Afterwards, noticed flames on driver's side door. Pulled over & parked. Turned vehicle off & flames stopped. Started vehicle & the fire reoccurred. Had to cut wires to stop the flames.
Upon starting up the van, driver heard a popping sound coming from the dash. Driver looked under the dashboard and noticed a fire in the wiring system. Driver was able to put out fire. Owner waiting for wiring harness to correct problem.
Started vehicle, within 5 seconds van filled with smoke and caught fire under dash. Final diagnosis from sam swope Ford in elizabethtown is that ignition switch shorted and burnt up wire harness under dash.
I already submitted this form earlier today, but I realized I made some errors on the form so here is an updated form with the correct information. As I explained on the first form, there are two related problems which have been occurring with our Ford Aerostar Mini van. The first problem is that the sliding side door does not close properly because the door guide-track is defective and has broken at the point where it attaches to the vehicle body behind the latch strike-pin. We had this repaired in December of 1998, but it has broken again only 15 months after the first repair. The other problem is failure of the electrical system, which is related to the door defect, because sometimes when the door is not latched properly, the door-ajar light comes on and makes a terrible grating/buzzing noise and at the same t ime causes all the electrical systems to fail. …
Related recalls
Electrical system › Wiring › Front underhood
Vehicle description: Mini vans. 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.
Remedy: 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 system › Ignition › Switch
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.
Remedy: Dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.
Electrical complaints in other Aerostar years
Frequently asked questions
How common are electrical problems on the 1995 Ford Aerostar?
NHTSA has 37 complaints about the electrical system of the 1995 Ford Aerostar, 24% of the model year's 157 complaints. The component named most often is ignition › switch (18 mentions).
Is there a recall for 1995 Ford Aerostar electrical problems?
Yes — NHTSA recall 99V-028 (front underhood, Feb 9, 1999); NHTSA recall 99V-029 (switch, Feb 9, 1999). Recall repairs are free at authorized dealers.
At what mileage do 1995 Ford Aerostar electrical problems start?
Half of the complaints with a recorded mileage happened before about 150,000 miles.
Is it dangerous?
Owners linked 0 crashes, 13 fires and 2 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.