1992 Ford Aerostar recalls & complaints

Component: SERVICE BRAKES, HYDRAULIC
Summary: CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Consequence: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
Notes: THIS RECALL ONLY PERTAINS TO AFTERMARKET NAPA, RAYBESTOS, AC DELCO, AIMCO, CARQUEST, AND BENDIX BRAKE HYDRAULIC MASTER CYLINDERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON DAIMLERCHRYSLER OR FORD VEHICLES. CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

Component: POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)
Summary: VEHICLE DESCRIPTION: ALL WHEEL DRIVE PASSENGER MINIVANS. (THIS INCLUDES ALL 1992 AWD AEROSTARS NOT PREVIOUSLY INCLUDED IN SAFETY RECALL 97V-204/97S83). 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. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Consequence: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
Notes: OWNER NOTIFICATION BEGAN JUNE 17, 1999. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Component: ELECTRICAL SYSTEM:IGNITION:SWITCH
Summary: 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.
Consequence: THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.
Remedy: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.
Notes: OWNER NOTIFICATION BEGAN MARCH 19, 1999. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Component: POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)
Summary: 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. FLUID EXPLUSION, DRIVESHAFT SEPARATION OR LOSS OF VEHICLE DRIVE CAN RESULT.
Consequence: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.
Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.
Notes: OWNER NOTIFICATION IS EXPECTED TO BEGIN FEBRUARY 16, 1998. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.

Component: SERVICE BRAKES, AIR:DISC:ROTOR
Summary: EQUIPMENT DESCRIPTION: AFTERMARKET BRAKE ROTORS FOR USE ON CERTAIN FORD AND MAZDA TRUCKS. CRACKED CASTINGS CAUSED CRACKS TO APPEAR ON THE OUTER DIAMETER OF THE ROTOR HAT OR AROUND THE STUD HOLE.
Consequence: LOSS OF BRAKING CAN RESULT.
Remedy: AIMCO WILL REIMBURSE CONSUMERS/INSTALLERS FOR THE COST OF REPLACEMENT ROTORS AND INSTALLATION. CONSUMERS ARE REQUESTED TO RETURN TO THE LOCATION WHERE THE ROTORS WERE ORIGINALLY PURCHASED/INSTALLED FOR REPLACEMENT.
Notes: OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING APRIL 1998. OWNERS WHO DO NOT RECEIVE THE FREE ROTORS WITHIN A REASONABLE TIME SHOULD CONTACT AIMCO AT 815-759-7935. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

09/06/2008 · Seat belts
SEATBELT DONT WORK. *TR

08/25/2008 · Engine
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. UPON PURCHASING THE VEHICLE, THE CONTACT STATED THAT THE MUFFLER WAS RUSTED AND CRACKED. THE DEALER STATED THAT THE VEHICLE WAS FINE AND THE FUMES WOULD EXIT OUT OF THE REAR OF THE VEHICLE. THE FIRE DEPARTMENT STATED THAT THE FUMES WERE ENTERING THE VEHICLE DUE TO THE HOLES. THE DEALER STATED THAT THEY SEALED TH…

08/13/2007 · Vehicle Speed Control · fire
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE CRUISE CONTROLS SHUTS ON AND OFF WITHOUT WARNING. SEVERAL YEARS AGO, HE WITNESSED BILLOWS OF SMOKE COMING FROM THE VEHICLE. THE VEHICLE HAS NOT BEEN INSPECTED OR REPAIRED. THE SPEED AND POWERTRAIN WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 145,681.

07/13/2007 · Electrical system
TL*THE CONTACT OWNS A 1992 FORD AEROSTAR. THE CONTACT STATED THAT THE GROUND WIRES ARE SHORTING OUT THE BRAKE LIGHTS AND OTHER WIRES UNDERNEATH THE DASHBOARD. HE ALSO STATED THAT HIS WINDOWS ARE NOT WORKING. FORD STATED THAT NOTHING COULD BE DONE BECAUSE HIS VIN WAS NOT INCLUDED IN THE RECALL. THE CONTACT STATED THAT HE HAS BEEN BURNED BY THE FAILED WIR…

07/19/2006 · Lights
DT*: THE CONTACT STATED THAT THE VEHICLE'S HORIZONTAL AND VERTICAL HEADLIGHT ADJUSTERS FRACTURED ON 07/04/06. THE VEHICLE WAS TAKEN TO THE DEALER ON 07/05/06 WHO DETERMINED THAT THERE WAS NO REPLACEMENT PART AVAILABLE TO REPAIR THE PROBLEM. THE TENSION SPRING THAT ASSISTS IN THE PROPER FUNCTIONING OF THE HEADLIGHT ADJUSTERS WAS NO LONGER AVAILABLE AS WELL…

03/20/2006 · Transmission / drivetrain
DT*: THE CONTACT STATED WHEN THE VEHICLE WAS PLACED IN DRIVE, IT FAILED TO MOVE FORWARD. THE VEHICLE CURRENTLY ONLY OPERATES IN REVERSE. THE VEHICLE WAS SEEN BY A LOCAL MECHANIC WHO DETERMINED THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION HAD GONE OUT PREVIOUSLY AND WAS REPLACED BY A LOCAL MECHANIC.

01/21/2005 · Brakes · crash
OWNER WAS GOING AT APPROXIMATELY 45 MPH. OWNER APPLIED THE BRAKES AND THE BRAKES WENT TO THE FLOOR. OWNER SAYS THAT THE FRONT RIGHT BRAKE HOSE LINE POPPED RIGHT OFF. CAUSING THE VEHICLE TO LOSE ALL BRAKE PRESSURE PREVENTING THE VEHICLE FROM STOPPING. PROVIDE FURTHER DETAILS. *NM

10/15/2004 · Wheels / tires · crash
DRIVER'S SIDE REAR TIRE EXPERIENCED A TREAD SEPARATION WHILE DRIVING 60-65 MPH, WITH TWO ADULTS AND ONE CHILD IN A FORD AEROSTAR 1992 VAN. THE TIRE REMAINED INFLATED. AFTERMARKET EQUIPMENT, INSTALLED AT 136,671 MILES, TIRE SIZE P215/70R14, DOT# DBHYC2423000. *AK *NM