Which parts fail
Components named in complaints (wheels, lug nuts, original-equipment tires, TPMS).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Ford Aerostar owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
Tl contact owns a 1996 Ford Aerostar. While driving 50 MPH, the contact heard a loud roaring sound. She stopped the vehicle and noticed that the rear passenger wheel spokes failed. The wheel was replaced with a spare tire. There was no damage to the tire or vehicle. The wheel was inspected by the repair shop and they stated that the wheel was defective. The wheels were the original wheels for the vehicle. The powertrain was unknown. The current and failure mileages were 58,000.
On 9/17/02 the right front alloy wheel cracked while on vacation. We were unable to travel in it. It was expensive and difficult to replace. On 2/1/03 (also out of town) the left back alloy wheel cracked. We are searching for a replaement. Our mechanic told us this should not happen and must be a manufacturing defect. There are several similair complaits please evaluate as it could cause a severe accident.
While driving 70 MPH, the rear driver side tire tread separated. The consumer managed to pull over to change tire. The dealership was notified, but did not resolve the problem. Please provide more information. Size#21570r14 dot#hyhy4fa229.
Dt*: the contact stated the front wheels on the vehicle cracked. This was noticed from a visual inspection by the contact. The manufacturer was alerted and stated the wheels cracked under stress from the vehicle.
These 2 tire failures occurred under normal driving cirucumstances on a vehicle that is regularly maintained at the Firestone service center that installed the tires. Firestone has denied claim of vehicle repair from the tire separation incident on June 16, 2002, saying the 'tire was improperly inflated for an undetermined time period'. Their own people inspected the tires 40 days prior, the time of the 1st tire separation, claiming tires to be worthy, properly inflated etc. We firmly believe that an investigation into these tires must happen, if it isnt already underway. This was a potentially dangerous situation that fortunately did not end tragically, other than dollars spent out of our pocket. …
Component #1: right rear passenger tire....I heard a thumping noise and pulled over to check.I found that the tire was failing on the inside causing a very large bubbling effect to occur which in turn was breaking the inner tire wires and pushing the tread out from the body of the tire. When I took it into tire kingdom, so. Us #1, ft. Pierce, I was told that it was cause from uneven outter wear---not!---and that since I had boiught the lower priced tire that that was all I could expect. I had to but a replacement tire. The same thing happened on 4/17/2001 to the driver front tire. Please bear in mind that all four of the tires on this vechicle were bout at the dame time and experience the same wear. I am concerned that this is a serious type of defect in the same vein as the Firestone failures and that had I been on the highway I and any passenger could have been killed. …
During a brake inspection at a tire store, it was pointed out that the original aluminum wheels were cracked. Two of the large spokes on one wheel were cracked through. One other was cracked but not all the way through. I called wendle Ford who had sold me the car. They said it wasn't a warranty item and they had never heard of such a failure before. I took the car to the dealer ship to show them the cracked wheels. They then told me that I was the second person today (January 14, 2000) who had the same problem with cracked wheels on an Aerostar, but it still isn't a warranty or recall item and they would be happy to sell me new wheels. I don't believe wheels should be cracking after 3 years. This is also a safety concern. Luckily the problem was found before it caused an accident. I have to believe that this problem is widespread if 2 of us in one day at one dealership had the problem.
My 1996 Ford Aerostar has 14x6 aluminum allow wheel rims. The rims have 7 triangular slots and 7 wide/flat "spokes". One of these rims is cracking. The crack is progressing from one spoke to another. I have stopped driving the vehicle all together. After almost a month of searching for a used replacement rim I have found out that I am not the only one with this problem. I suspected that this May be the case when I could not find any on-line company that had these in stock (used or new). Today I spoke with a woman at ackerwheels.com and learned that this rim can only be purchased from the dealer. She warned me that if I ordered one from the dealer to look it over carefully for cracks. I asked her if this was a common problem. She said it was and that I should not expect Ford to recall it. I believe that all of my other three rims are now suspect. What can you do?
Wheel & Tire complaints in other Aerostar years
Frequently asked questions
How common are wheel & tire problems on the 1996 Ford Aerostar?
NHTSA has 28 complaints about the wheels & tires of the 1996 Ford Aerostar, 27% of the model year's 104 complaints. The component named most often is rim (8 mentions).
Is there a recall for 1996 Ford Aerostar wheel & tire problems?
No. NHTSA lists no wheels & tires recall for the 1996 Ford Aerostar, though it has 4 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Ford Aerostar wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 124,000 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.