Most common 1996 Ford Aerostar problems
Share of the 104 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford Aerostar complaints by model year
Best Aerostar years: 2000, 1999. Years to avoid: 1995, 1996. Compare all years →
1996 Ford Aerostar recalls (4)
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.
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.
Equipment › Other › Labels
The certification labels on the involved vehicles has incorrect rear tire inflation pressure designations. This does not comply with FMVSS no. 120, "tire selection and rims for motor vehicles other than passenger cars."
Remedy: Owners will be provided with correct certification labels and instructions for installing these labels. Dealers can install this label if the owner so desires.
Latches/locks/linkages › Doors › Latch
When in the secondary latched position, the driver door latches May open when subjected to transverse loads less than that specified in FMVSS no. 206, "door locks and door retention components."
Remedy: Dealers will inspect and, if necessary, replace the driver door latch.
NHTSA defect investigations
Federal safety investigators have looked into 2 possible defects involving the 1996 Ford Aerostar:
Transfer cases and rear driveshaft
There is no summary currently available
Transfer cases and rear drive shaft
There is no summary currently available
What 1996 Ford Aerostar owners say
Wheels & tires all 28 →
I noticed a "pinhole" on my viper gt tires, contacted the dealer where I purchased them, they told me that they were not on a recall list but would replace them for a "difference" cost. I researched the internet and discovered that 1-2 years earlier cooper (the manufacturer) gad a recall on a similar issue. The dot number of the tires that had on my van were as follows: 30 hy udn2802 - this tire had no noticable pinhiole 30 hy udn2401 - pinhole with visible wire threads visible 30 hy udn2402 - pinhole with visible wire threads visible 30 hy udn3001 - pinhole but no visible wires showing yet.
Condensed version: @ 70mph posted speed limit Goodyear allegra touring tire exploded like a 1/4 stick of dynamite and almost cost me my life if my reactionary time had been any slower. 3 other tires same leaking through sidewall Goodyear decorative gills on same this has not resolved. Seller has not resolved and refuses though Goodyear said to replace before the main issue of the left front driver tire exploding at 70 MPH, . Litigation is next step if amicable resolution can not be had. Contact has been extensive with Goodyear to no results.
Brakes
While consumer was backing out vehicle hit a steel pole. Within second vehicle suddenly accelerated in a foward position, while driver's foot remained on brake, vehicle hit the wall of warehouse. Dealer / manufacturer were not contacted at this time.
As promised, I'm back. Major brake failures at 32,518, 55,638, and recently at 58, 700. I checked your site through the cartalk website and found 12 brake problems reported out of 79. I am not the only owner whose family is at risk. Mosy recently, the brake pedal bottomed out two consecutive times at slow speed. The passengers in the car said they smelled heated brakes. I believe the calipers May be dragging, overheating the brakes. I cannot duplicate the problem. We owned an Aerostar previously and had no such brake problems, certainly not a pad replacement at 32,000. These brakes are wearing prematurely. Although the car was under warranty, we were charged for pad replacement and rotor resurfacing. Ms brenner, the principal driver noticed a grinding sound which cased her to take it in for service. …
Electrical system
I had smoke and acrid smell coming from under my dash (while driving), where the steering column fits to it. I have contacted a major Ford dealer (brandon Ford), and they are refusing to help me. I called Ford customer service and he said my VIN is not listed for a recall, but yet had no answer for me when I asked why is my vehicle not on the recall list, when it is in the group of vehicles that were recalled and that are catching on fire while driving down the road. Over 887,000 were recalled for fire related problems, but they refuse to even look at mine. So, can I keep driving it? I don't know if it was a one time thing, or what.....
Dt*: the contact stated while the vehicle was being driven 30 MPH, all power failed and the engine stalled. The stalling has also occurred at higher speeds and while the vehicle was immobile. A fuse connected to the battery cables blew. When the fuse was replaced, the engine would restart. The vehicle was taken to the service dealer. The contact was informed the vehicle was not included in recall # 99V029000, for the electrical ignition switch due the VIN even thought vehicle had the same problems. The manufacturer was not notified.
1996 Ford Aerostar engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 3.0L 6-cyl | 4-speed automatic | RWD | 16 / 22 / 18 |
| 4.0L 6-cyl | 4-speed automatic | RWD | 15 / 21 / 17 |
| 4.0L 6-cyl | 4-speed automatic | 4WD/AWD | 13 / 19 / 15 |
EPA ratings. Class: Van.
Frequently asked questions
Is the 1996 Ford Aerostar a good car?
Based on 104 owner complaints filed with NHTSA, the 1996 Aerostar rates avoid: 2.8× as many complaints as a typical year of the Aerostar at the same age. It is one of the Aerostar years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 1996 Ford Aerostar?
The wheels & tires — 28 complaints, 27% of all complaints for this model year, most often about rim. Next are the brakes (18) and electrical system (12).
How many recalls does the 1996 Ford Aerostar have?
There are 4 recalls for the 1996 Ford Aerostar, the most recent from February 9, 1999 (switch). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford Aerostar?
The best years by complaints, compared at the same age, are 2000 and 1999. Years to avoid or approach with caution: 1995 and 1996. See the full Ford Aerostar years comparison.
At what mileage do 1996 Ford Aerostar problems happen?
The median mileage reported in complaints is about 124,000 miles; 0% of problems with a recorded mileage started before 50,000 miles.
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.