What are the common problems with the 1991 Ford Aerostar?
Owners of the 1991 Ford Aerostar have filed 223 complaints with NHTSA, most often about the electrical system (67) and the powertrain (49). In NHTSA's complaints file of November 11, 2026, 2 of its 223 complaints list a mileage (105,410 to 150,000 miles), too few to say when problems were reported; a complaint is an owner's report, not a proven defect.
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See what the paid report includes →NHTSA's file holds 223 owner complaints on the 1991 Ford Aerostar. Owners named the electrical system most often: 67 complaints. A complaint can name more than one component. Of the 223 complaints, 23 report a crash, 70 report a fire and 14 report an injury (25 people reported injured). These are owners' reports to NHTSA, not findings.
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Common problems with the 1991 Aerostar
NHTSA's file holds 223 owner complaints on the 1991 Ford Aerostar. Owners named the electrical system most often: 67 complaints. A complaint can name more than one component.
| Component (NHTSA category) | Complaints | Listing mileage | Median mileage |
|---|---|---|---|
| Electrical System | 67 | 0 | Under 5 mileages |
| Power Train | 49 | 0 | Under 5 mileages |
| Service Brakes, Hydraulic | 31 | 1 | Under 5 mileages |
| Vehicle Speed Control | 23 | 0 | Under 5 mileages |
| Equipment | 14 | 0 | Under 5 mileages |
Of the 223 complaints, 23 report a crash, 70 report a fire and 14 report an injury (25 people reported injured). These are owners' reports to NHTSA, not findings.
Mileage when owners reported a problem with the 1991 Aerostar
Too few complaints on the 1991 Aerostar list a mileage to say when owners reported problems: 2 of its 223 complaints list a mileage (105,410 to 150,000 miles), and a median is given here only with 10 or more.
These mileages say when owners reported a problem, not when a 1991 Aerostar wears out. NHTSA's file holds only vehicles whose owners complained; one that ran without a problem never appears in it, so it gives no lifespan and no cutoff, and how a vehicle was maintained matters more than any one odometer reading.
Is the 1991 Aerostar a good year?
Complaint counts cannot say whether the 1991 is a good or a bad Aerostar: they rise with how many were sold and how long they have been on the road. They show how the 1991 compares with the other model years in NHTSA's file.
With 223 complaints, the 1991 ranks 5th of the 12 Ford Aerostar model years from 1986 to 1997 with 10 or more complaints, counting from the most. The most: the 1993 (374). The fewest: the 1986 (53).
Recent model years have had less time to collect complaints, so their counts are still growing. No year is ranked by mileage here, because a year's median mileage mostly follows its age.
| Model year | Owner complaints | Listing mileage | Median mileage |
|---|---|---|---|
| 1986 Aerostar | 53 | 1 | Under 10 mileages |
| 1987 Aerostar | 114 | 0 | Under 10 mileages |
| 1988 Aerostar | 177 | 8 | Under 10 mileages |
| 1989 Aerostar | 260 | 6 | Under 10 mileages |
| 1990 Aerostar | 195 | 5 | Under 10 mileages |
| 1991 (this page) | 223 | 2 | Under 10 mileages |
| 1992 Aerostar | 317 | 12 | 145,681 |
| 1993 Aerostar | 374 | 18 | 144,670 |
| 1994 Aerostar | 257 | 15 | 109,089 |
| 1995 Aerostar | 157 | 10 | 140,000 |
| 1996 Aerostar | 104 | 14 | 115,000 |
| 1997 Aerostar | 63 | 11 | 99,000 |
1991 Ford Aerostar recalls
NHTSA's recall files of November 11, 2026 list 4 recall campaigns that name the 1991 Ford Aerostar (3 vehicle campaigns and 1 equipment or tire campaign that names this model year, often for aftermarket parts). A campaign covers a production range, not every vehicle of the model year: check the VIN with NHTSA's free recall lookup.
| Campaign | Report received | Component |
|---|---|---|
| 98E010000 | Apr 8, 1998 | SERVICE BRAKES, AIR:DISC:ROTOR |
| 96V071000 | Apr 25, 1996 | ELECTRICAL SYSTEM:IGNITION |
| 91V189000 | Nov 4, 1991 | POWER TRAIN:AUTOMATIC TRANSMISSION |
| 91V164000 | Sep 20, 1991 | SEAT BELTS:FRONT:ANCHORAGE |
What these figures can and cannot tell you
- Complaints are owners’ reports to NHTSA. NHTSA publishes them without verifying them: a complaint is an allegation, not a defect finding.
- The mileage is what the owner wrote on the complaint; NHTSA does not check it against the odometer.
- The make, model and model year are the ones on the complaint. NHTSA records them as filed, so a few complaints sit under a model year the name was not sold in.
- They are not a lifespan study. The file holds only vehicles whose owners reported a problem, so these figures do not say how long a typical 1991 Aerostar lasts.
- A complaint count rises with how many vehicles were sold and how long they have been on the road, so it is not a rating of the 1991 Aerostar.
- Nothing here describes one vehicle: its title brands, odometer readings, accidents and open recalls are in the records for its own VIN.
- 221 of the 223 complaints on the 1991 Ford Aerostar give no usable mileage (blank, zero, a filler such as 999999, or over 500,000) and are left out of every mileage figure.
- NHTSA name counted: AEROSTAR. NHTSA files some vehicles under several names (a series name and a trim name, for example); this page counts only this one.
- Recall-file name matched: AEROSTAR.
Primary sources behind this page
Open the underlying public source and verify that its scope matches the question you are asking.
- NHTSA complaints flat file (FLAT_CMPL.zip), downloaded November 11, 2026National Highway Traffic Safety Administration
- Complaints file field layout (CMPL.txt)National Highway Traffic Safety Administration
- NHTSA recalls flat file (FLAT_RCL_PRE_2010.zip), downloaded November 11, 2026National Highway Traffic Safety Administration
- NHTSA recalls flat file (FLAT_RCL_POST_2010.zip), downloaded November 11, 2026National Highway Traffic Safety Administration
- Recalls file field layout (RCL.txt)National Highway Traffic Safety Administration
- NHTSA recall and complaint datasets: scope and documentationNational Highway Traffic Safety Administration
- Recalls Lookup by VINNational Highway Traffic Safety Administration
NHTSA’s complaints file was downloaded on November 11, 2026 (FLAT_CMPL.txt, dated 2026-11-11 10:15, 2,265,416 rows), with its recall files (FLAT_RCL_PRE_2010.txt and FLAT_RCL_POST_2010.txt, dated 2026-11-11 08:02). Each complaint is counted once, by its NHTSA number, with the model year and mileage of its first row; a model year has a page only with 10 or more complaints. The collection script and its rules are in scripts/collect-nhtsa-model-year-longtail.mjs.
1991 Ford Aerostar questions
What are the most common 1991 Ford Aerostar problems?
NHTSA's file holds 223 owner complaints on the 1991 Ford Aerostar. Owners named the electrical system most often: 67 complaints. A complaint can name more than one component. Of the 223 complaints, 23 report a crash, 70 report a fire and 14 report an injury (25 people reported injured). These are owners' reports to NHTSA, not findings.
At what mileage do owners report problems with the 1991 Ford Aerostar?
NHTSA's file gives no mileage figure for the 1991 Ford Aerostar: 2 of its 223 complaints list a mileage (105,410 to 150,000 miles), and this page gives a median only with 10 or more. These are mileages at a reported problem; they do not say how many miles a 1991 Aerostar can cover.
Is the 1991 Ford Aerostar a good year?
Complaint counts cannot say whether the 1991 is a good or a bad Aerostar: they rise with how many were sold and how long they have been on the road. They show how the 1991 compares with the other model years in NHTSA's file. With 223 complaints, the 1991 ranks 5th of the 12 Ford Aerostar model years from 1986 to 1997 with 10 or more complaints, counting from the most. The most: the 1993 (374). The fewest: the 1986 (53).
How many recalls does the 1991 Ford Aerostar have?
NHTSA's recall files of November 11, 2026 list 4 recall campaigns that name the 1991 Ford Aerostar (3 vehicle campaigns and 1 equipment or tire campaign that names this model year, often for aftermarket parts). A campaign covers a production range, not every vehicle of the model year: check the VIN with NHTSA's free recall lookup.
How do I check a used 1991 Ford Aerostar before buying?
Take the 17-character VIN from the vehicle and compare the odometer with the readings on file for it: title transfers, inspections and auction sales record the mileage on the day. VIN Lookup (free-vin-lookup.com) sells the original ClearVIN PDF for $14.99 (3 reports for $29.99, 5 for $44.99): odometer readings, title brands and auction records on file for the VIN. Check the VIN before buying a used 1991 Ford Aerostar.