Electrical complaints by model year
Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
What owners report
My 1997 Ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. The Ford dealer did the recall work but did not fix or examine the steering column or the components that burned or over heated as a result of the overload. [redacted] updated 07/19/2012
I found two incomplete recalls. I called the dealer 9/28/2020 at [redacted] and spoke to [redacted]. She put the VIN in her system, saw the two recalls and said the parts would be ordered. No response. I call [redacted] 10/5/2020 at the same number and she said about the same thing. Then I called 10/8/2020 and another service advisor printed out the issue with my phone number [redacted] and said [redacted] would call me after lunch. No response. I tried calling the Ford customer service [phone] and after pressing '#' for two commercials, the recorder hung up. The vehicle has been running fine, but these are two recalls that are concerns. (00s56 & 99s02). Thank you very much. [redacted]augusta, ga
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.
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.
Related recalls (2)
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.
Frequently asked questions
Which Ford Aerostar years have electrical problems?
By NHTSA complaints, the 1995 (37), 1997 (13) and 1996 (12) model years. Electrical complaints make up 24% of all complaints for the 1995.
Is there a recall for Ford Aerostar electrical problems?
Yes — 2 recalls, including 99V-028 (front underhood, Feb 9, 1999); 99V-029 (switch, Feb 9, 1999). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Ford Aerostar electrical problems start?
Across all years, half of the complaints with a recorded mileage happened before about 133,000 miles; 0% happened before 50,000 miles.
What part fails most often?
Owners most often name the ignition › switch (29 mentions), followed by the ignition (11).
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.