1990 Ford Aerostar problems & reliability
195 owner complaints filed with NHTSA for the 1990 Ford Aerostar. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
13 complaints report injuries (20 injured).
Federal crash records (FARS 2020–2023): 1990 Ford Aerostar vehicles were involved in 1 fatal crash with 1 occupant death. Involvement counts are not adjusted for how many are on the road and do not imply fault or a vehicle defect.
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Electrical System | 56 | 29% |
| Power Train | 37 | 19% |
| Service Brakes, Hydraulic | 27 | 14% |
| Fuel System, Gasoline | 26 | 13% |
| Engine and Engine Cooling | 16 | 8% |
| Vehicle Speed Control | 16 | 8% |
| Steering | 8 | 4% |
| Visibility | 8 | 4% |
| Seat Belts | 5 | 3% |
| Structure | 4 | 2% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Complaints by incident year
What owners report
“1990 ford aerostar. Consumer states sudden acceleration nearly 20 years ago, that caused over $1,000 in damage. Tgw the consumer stated the accident happened when the vehicle was idling. *jb”
Vehicle Speed Control · filed Apr 12, 2010
“1990 ford aerostar had crack in fuel tank causing consumer to replace the tank. ***no answer required*** *ts the consumer received a recall letter in dec 1998 regarding the gas tank, however at the time he was not experiencing problems with the gas tank. The consumer is now requesting reimbursement for the gas tank…”
Fuel System, Gasoline · filed Nov 4, 2005
“My 1990 ford aerostar was leaking gasoline. The fumes would overcome you while inside the vehicle. After the van sat for a short time gas would be all over the ground from the leak. I paid a ford dealer to replace the tank not knowing there was a recall. The safety of my family was important enough that I paid this…”
Fuel System, Gasoline · filed Aug 1, 2005
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- TRANSFER CASES AND REAR DRIVE SHAFT
Engineering Analysis EA99002 · opened Jan 7, 1999 · closed Nov 14, 2000 · led to recall 99V094000
- CRACKED FUEL TANKS
Engineering Analysis EA96030 · opened Dec 20, 1996 · closed Aug 13, 1998 · led to recall 98V190000
- CRACKED FUEL TANKS
Preliminary Evaluation PE96050 · opened Aug 6, 1996 · closed Dec 20, 1996
- PARK PAWL BENDING
Preliminary Evaluation PE91127 · opened Sep 16, 1991 · closed Nov 8, 1991 · led to recall 91V189001
- LIFTGATE FAILURE
Engineering Analysis EA91015 · opened Feb 1, 1991 · closed Sep 20, 1991 · led to recall 91V136000
Technical service bulletins
46 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 1990 Ford Aerostar. The 10 most recent:
Some vehicles equipped with the 4.0l ohv engine may exhibit an engine noise which may be perceived by the customer as a piston / onnecting rod bearing knock. *tt
01197 · Service Bulletin/Repair Instructions · issued Oct 1, 2001
Information regarding transmission fluid usage charts. *slc
01157 · Service Bulletin/Repair Instructions · issued Aug 6, 2001
Some vehicles may exhibit heater core leaks. *slc
01156 · Service Bulletin/Repair Instructions · issued Aug 6, 2001
On some vehicles, engine oil may continue to leak from the engine oil pan gasket area after an engine oil pan gasket repair has been performed. *tt
01124 · Service Bulletin/Repair Instructions · issued Jun 25, 2001
Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt
002310 · Service Bulletin/Repair Instructions · issued Nov 13, 2000
Information regarding the new transmission cooler flusher- service tip. *mjs
0015 · Service Bulletin/Repair Instructions · issued Jan 10, 2000
Subject on a wire harness terminal repair kit available for repairing electrical wiring harnesses. *tt
99222 · Service Bulletin/Repair Instructions · issued Oct 18, 1999
Information on identifying non-approved / alternate refrigerants which could cause safety, and performance concerns if installed in ford a/c systems. *tt
99196 · Service Bulletin/Repair Instructions · issued Sep 20, 1999
Service tip information on revised oil pan gasket replacement procedure. *tt
99183 · Service Bulletin/Repair Instructions · issued Sep 6, 1999
Some vehicles may exhibit an engine noise which may be perceived by the customer as a piston / connecting rod bearing knock. *tt
13118 · Service Bulletin/Repair Instructions · issued Aug 1, 1999
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
No NHTSA recall campaigns name the 1990 Ford Aerostar in our current data. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 1990 Ford Aerostar?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.