What are the most common Ford Aerostar problems?
According to Au7o's analysis of 555+ owner reports, the 1991 Ford Aerostar has 6 documented issues. The most frequently reported are: A4LD Automatic Transmission Premature Failure, Head Gasket Failure and Coolant Leakage, Park Pawl May Fail to Engage the Park Gear (NHTSA Recall 91V189000). Of these, 4 are rated critical and should be addressed promptly.
Is the Ford Aerostar reliable?
The 1991 Ford Aerostar has 6 known issues documented across 555+ owner reports. 4 issues are rated critical: A4LD Automatic Transmission Premature Failure and Head Gasket Failure and Coolant Leakage and Park Pawl May Fail to Engage the Park Gear (NHTSA Recall 91V189000) and In-Tank Fuel Pump Failure. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford Aerostar problems?
Repair costs for known Ford Aerostar issues range from $200 to $3,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, A4LD Automatic Transmission Premature Failure, typically costs $1,200-$3,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 1990-1997 Ford Aerostar A4LD Automatic Transmission Premature Failure?
The Ford A4LD 4-speed automatic transmission used in early Aerostars (and the 4R44E/4R55E in later models) is known as one of Ford's weakest automatic transmissions. The overdrive band and servo fail prematurely, causing loss of overdrive. The forward clutch pack also wears rapid… Repairs typically run $1,200-$3,000. Severity: high.
What is the 1990-1997 Ford Aerostar Head Gasket Failure and Coolant Leakage?
Both the 3.0L Vulcan V6 and 4.0L Cologne V6 in the Aerostar are prone to head gasket failure, particularly after 100,000 miles. The 4.0L OHV engine is more susceptible due to its pushrod design creating uneven thermal expansion between the iron block and heads. Coolant leaks exte… Repairs typically run $800-$2,000. Severity: high.
What is the 1989-1991 Ford Aerostar Park Pawl May Fail to Engage the Park Gear (NHTSA Recall 91V189000)?
1989-1991 Ford Aerostar vans with automatic transmissions are included in NHTSA safety recall 91V189000. The defect is in the parking mechanism itself: with the shift lever placed in Park, the park pawl does not always abut or engage the park gear, so the transmission may not act… Severity: high.
What is the 1990-1997 Ford Aerostar In-Tank Fuel Pump Failure?
The in-tank electric fuel pump fails, causing no-start conditions or stalling at highway speed. The fuel pump relay can also fail with similar symptoms. Common on higher-mileage Aerostars. Repairs typically run $200-$500. Severity: high.
What is the 1990-1997 Ford Aerostar Rear Axle Bearing Failure and Axle Seal Leak?
The Aerostar uses a Dana 35 IFS rear axle (RWD) or Dana 28 front/35 rear (AWD) that develops bearing noise and axle seal leaks at moderate mileage. The C-clip axle retention design means a failed bearing can allow the axle shaft to slide out of the housing. Gear oil leaks past wo… Repairs typically run $300-$800. Severity: medium.
What is the 1990-1997 Ford Aerostar Front Ball Joint Wear?
The front upper and lower ball joints wear out prematurely, causing clunking noises over bumps, loose steering feel, and uneven tire wear. The RWD-based front suspension design puts high loads on these components. Repairs typically run $200-$500. Severity: medium.
