Which parts fail
Components named in complaints (automatic and manual transmissions, CVT, axles, driveshaft, 4WD/AWD).
Owner reports
Selected complaints filed with NHTSA by 1995 Ford Aerostar owners, lightly cleaned up (personal details are redacted by NHTSA).
Ford refunded us $1000.00 for 1 transmission, the first one was still on warranty, the most recent transmission failure occured at 55 miles per hour and it was the tourque converter that blew in this case.
This vehicle is exhibiting some of the same symptoms as previously experienced with the recall number indicated (97V204000). This recall was done in early March 1998. The resonance, which occures while the vehicle is neither being pulled by the drive train nor the engine being pushed by the drive wheels(floating between acceleration and decelleration), is begining to be in the drive train, just as it had been before the recall. Is it possible that the recall procedure was incorrect, or not completely engineered? Gibbons motor sales, dickson city, pa has in my past experience been competent. They were the servicing dealer. I feel that the problem is returning. I am unsure if the company would be obligated to repair this problem again?
Continual loss of torque over last seven months. Dealer has always said it was the small engine until on 5-1-00 it refused to take off when stopped at a stop sign and had a leak coming from the transmission. Leak later stopped and a check of the fluid level showed it to be normal. Ron clark Ford checked it out today and said the torque converter and entire transmission was worn out and estimated replacement at $2,800 for a rebuilt transmission. It was brought to their attention that each time we have taken it in for a check for the symptom that lead to this failure we have been told that nothing could be found wrong.
Consumer took vehicle in for recall on transfer case, recall no.97V204000. Vehicle was repaired, but problem reoccurred. Upon deceleration from speeds 55 to 70 MPH, creates a grining noise in the area where the parts were replaced, consumer is concerned that current parts would fail and cause problems controlling the vehicle, consumer states that the grining noise was not occurring before the factory recall and parts replacement.
Recall 97V204000: transfer case: recall been repaired twice by two Ford dealers quality Ford, whiteville, nc and pervis brothers, fayetteville, nc [phone]. The problem is still occurring, remedy did not fix the safety defect. Owner has been trying to get rid of the van, dealer would not take it for a trade in.
Consumer found out through a technical service bulletin that transmission had a design flaw. They had to alter the original design to repair the problem. Opening to transmission pump was too small, allowing the pump to become clogged up. It built presure to blow the front seal.
Consumer received recall letter for transfer case/drive shaft,consumer called two dealers for an appointment. Both refused to order the part until they have a primary inspection. Recall letter stated that the vehicle must be serviced without delay.
Consumer had new tires put on vehicle due to vibration, problem still exist. However, the drive shaft / transfer case was replaced which was the cause of the vehicle experiencing sudden acceleration and vibration, prior to recall notice (97v-204).
Transmission has been replaced 4 times.vehicle stalled in middle & when going in reverse. Problem is intermittent. Dealer just rebuilds transmission, not knowing if parts are defective.
Received recall notice 97V204000 concerning 4-wheel drive & contacted dealer. Took vehicle to dealer for repairs. Picked up vehicle. Was not satisfied with the recall repairs.
Related recalls
Power train › Transfer case (4-wheel drive)
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.
Remedy: Dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
NHTSA investigations
Transfer cases and rear driveshaft
There is no summary currently available
Transfer cases and rear drive shaft
There is no summary currently available
Transmission complaints in other Aerostar years
Frequently asked questions
How common are transmission problems on the 1995 Ford Aerostar?
NHTSA has 22 complaints about the transmission & drivetrain of the 1995 Ford Aerostar, 14% of the model year's 157 complaints. The component named most often is automatic transmission (9 mentions).
Is there a recall for 1995 Ford Aerostar transmission problems?
Yes — NHTSA recall 97V-204 (transfer case (4-wheel drive), Nov 13, 1997). Recall repairs are free at authorized dealers.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to transmission & drivetrain 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.