1990-1997 Ford Aerostar: Full Review
Updated: 11/23/08
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Learn about the year-to-year changes and reliability for the 1990-1997 Ford Aerostar and our price chart details a range of prices based on vehicle mileage and condition.
Pros
- Passenger room
- Cargo room (extended-length)
- Optional AWD traction
- Trailer-towing capability
Cons
- Fuel economy
- Entry/exit
- Ride
Vehicle Highlights
Introduced way back in 1986, Ford's rear-drive minivan came in both passenger and cargo-hauling form. A stretched van joined the original for 1989, on the same 118.9-inch wheelbase but with 15.4 inches tacked onto the rear. An available 4.0-liter V6 and heavy-duty 4-speed automatic transmission arrived for 1990. Also new for 1990: full-time 4-wheel drive (as an option) and standard antilock rear brakes. Seating for five was standard; space for seven optional. Six trim levels were available.
Expert Ratings Summary (view detailed report)
| Category | Ford Aerostar ext. 4WD Rating | |
|---|---|---|
| Performance | 3 | |
| Fuel Economy | 3 | |
| Ride Quality | 4 | |
| Steering/Handling/Braking | 3 | |
| Quietness | 4 | |
| Controls/Materials | 4 | |
| Interior Room | 5 | |
| Room/Comfort (rear) | 5 | |
| Cargo Capacity | 8 | |
| Value within Class | 4 | |
| Total Score: | 43 |
Learn about the year-to-year changes of the 1990-1997 Ford Aerostar. Get full details of the styling and performance changes throughout the history of the 1990-1997 Ford Aerostar.
Year to Year Changes
1991 Ford Aerostar:
A new sport appearance package for regular-length XL and XLT included forged alloy wheels and silver-color body accents (including a front air dam and side running boards). A door ajar light was added for models with dual rear doors.
1992 Ford Aerostar:
A driver-side airbag and front-end facelift came for '92. The new dashboard got redesigned headlamp and climate controls. The automatic-transmission shift lever moved from the floor to the steering column. High-back front buckets now were standard. Rear outboard seats got lap/shoulder belts. A new grille and flush aero headlamps were installed.
1993 Ford Aerostar:
New optional integrated child safety seats became available, folding out from the middle bench.
1994 Ford Aerostar:
A high-mounted third brake light was installed for '94. Aerostars still came in XL, XL Plus, XLT, and Eddie Bauer trim.
1995 Ford Aerostar:
Produced in regular or extended form, the Aerostar XLT complemented Ford,s new front-drive Windstar minivan. Side-impact beams were added to both front doors and the sliding side door. Permanent 4-wheel drive remained available, only in extended-length models. No more manual-shift Aerostars went on sale.
1996 Ford Aerostar:
A new 4-speed automatic transmission with electronic shift controls became available. Radios got larger buttons. Optional premium sound systems were upgraded to 24 watts. The optional auto-climate system was redesigned with new air conditioning controls.
1997 Ford Aerostar:
A new 5-speed automatic transmission arrived for '97, which turned out to be Aerostar,s final season. The 5-speed came only with the 4.0-liter engine, which was standard on 4WD Aerostars. This minivan was discontinued at the end of the year.
Our road test for the 1990-1997 Ford Aerostar includes a full evaluation from the inside out. We've evaluated every aspect of the 1990-1997 Ford Aerostar and highlighted the vehicle's performance with pros and cons. Use our comprehensive road test ratings to decide if this generation 1990-1997 Ford Aerostar is right for you.
Consumer Guide® Road-Test Evaluation
The 3.0-liter engine produces adequate muscle, but the extra grunt of a 4.0-liter V6 is welcome, helping to haul around the hardware of the available 4-wheel-drive system. Don't expect great gas mileage with either engine: around 15 mpg in city/suburban driving, or low 20s on the highway. Poor traction can be a problem in rain or snow with the rear-drive Aerostar. Ride quality is another drawback, even with the Aerostar's long wheelbase. Suspensions are not very compliant, producing a rather harsh experience over bumps, though an Aerostar is stable and well-controlled. Cabins are roomy. Seven people can sit without squeezing, and the XLT and Eddie Bauer models contain plush and comfortable interior furnishings. Getting into the front seats requires a high step up. Cargo space is unimpressive in standard-size models, when all seats are in place.
Value for the Money
Aerostar and the Chevrolet Astro/GMC Safari are better suited to heavy-duty work, such as hauling hefty payloads or towing trailers (up to 4800 pounds), than the league-leading front-drive Chrysler minivans.
Aerostar and the Chevrolet Astro/GMC Safari are better suited to heavy-duty work, such as hauling hefty payloads or towing trailers (up to 4800 pounds), than the league-leading front-drive Chrysler minivans.
Expert Ratings Summary
| Category | Ford Aerostar ext. 4WD Rating | |
|---|---|---|
| Performance | 3 | |
| Fuel Economy | 3 | |
| Ride Quality | 4 | |
| Steering/Handling/Braking | 3 | |
| Quietness | 4 | |
| Controls/Materials | 4 | |
| Interior Room | 5 | |
| Room/Comfort (rear) | 5 | |
| Cargo Capacity | 8 | |
| Value within Class | 4 | |
| Total Score: | 43 |
Each vehicle report contains one rating chart for representative model. Consumer
Guide® rates in ten key areas: Performance, Fuel Economy, Ride Comfort, Steering
and Handling, Interior Noise, Controls and Materials, Driver Room, Passenger Room,
Cargo Capacity, and Insurance Costs. These ratings compare the particular vehicle
rated to ALL other vehicles, not a vehicle's standing in a particular class. In the
ratings table, "1" is the lowest rating and "10" is the highest rating.
Our reliability study for this generation Ford Aerostar includes details on average repair costs, manufacturer recalls, and everything you need to know to gauge the long-term reliability of this generation Ford Aerostar .
Trouble Spots
Consumer Guide's® Auto Editors have scoured repair bulletins and questioned mechanics to search
for commonly occurring problems for a particular vehicle. In some cases we also give possible manufacturer-suggested
solutions. In many instances these trouble spots are Technical Service Bulletins posted by the manufacturer,
however, we have our own expert looking at additional vehicle problems.
Air conditioner:
Air conditioner compressors are prone to failure if there is not enough A/C oil in the system. (1994-97)
Audio system:
Whining noises in the radio speakers is caused by the gas tank fuel pump. An electronic noise filter must be installed on the fuel pump. (1990-96)
Engine noise:
The dash panel rattles or buzzes due to interference between the trim on the front pillar and the side quarter glass. (1992-96)
Engine noise:
A hammering noise and erratic temperature gauge reading is caused by a weak water pump. A revised pump is available. (1994-97)
Steering noise:
A clanging noise comes from the power steering cooler. A replacement will eliminate the noise. (1990-96)
Consumer Guide® Estimated Repair Costs
This table lists costs of likely repairs for comparison with other vehicles. The
dollar amount includes the cost of the part(s) and labor (based on $50 per hour) for the
typical repair without extras or add-ons. Like the pricing information, replacement
costs can vary widely depending on region. Expect charges at a new-car dealership
to be slightly higher.
| Item Name | Repair Cost |
| A/C Compressor | $410 |
| Alternator | $315 |
| Automatic Transmission or Transaxle | $775 |
| Brakes | $305 |
| Clutch, Pressure Plate, Bearing | $450 |
| Exhaust System | $445 |
| Radiator | $360 |
| Shocks and/or Struts | $255 |
| Timing Chain or Belt | $400 |
| Universal Joints | $160 |
Our price chart for this generation Ford Aerostar details a range of prices in
year-by-year listings based on vehicle mileage and condition.
| Prices | Good | Average | Poor |
|
|
|||
| 1997 | |||
| Aerostar extended | $2,400-3,000 | $1,700-2,200 | $500-600 |
| Aerostar regular | $2,000-2,500 | $1,400-1,800 | $300-400 |
| 1996 | |||
| Aerostar extended | $2,100-2,600 | $1,500-1,800 | $400-500 |
| Aerostar regular | $1,800-2,300 | $1,200-1,600 | $300 |
| 1995 | |||
| Aerostar extended | $1,800-2,300 | $1,200-1,600 | $300 |
| Aerostar regular | $1,600-2,000 | $1,100-1,300 | $200-300 |
| 1994 | |||
| Aerostar extended | $1,600-2,100 | $1,100-1,400 | $200-300 |
| Aerostar regular | $1,400-1,800 | $900-1,200 | $200 |
| 1993 | |||
| Aerostar extended | $1,500-1,900 | $1,000-1,200 | $200 |
| Aerostar regular | $1,300-1,700 | $800-1,100 | $200 |
| 1992 | |||
| Aerostar extended | $1,400-1,800 | $900-1,200 | $200 |
| Aerostar regular | $1,200-1,600 | $700-1,000 | $100-200 |
| 1991 | |||
| Aerostar extended | $1,200-1,600 | $700-1,000 | $100-200 |
| Aerostar regular | $1,100-1,500 | $700-900 | $100-200 |
| 1990 | |||
| Aerostar extended | $1,100-1,500 | $700-900 | $100-200 |
| Aerostar regular | $1,000-1,400 | $600-800 | $100 |
|
|
|||
This chart details a range of prices in year-by-year listings for vehicles in three condition levels:
Good: a clean low-mileage, solid-running vehicle that needs little or no repair.
Average: a car with normal miles on the odometer, perhaps a few scrapes or dings;
engine might need a minor repair or two, but runs acceptably well.
Poor: might have potentially dangerous problems with the engine and/or body, or
abnormally high mileage; definitely in need of mechanical attention. Valuations
reflect wholesale prices paid by dealers at auction, and retail prices on used-car
lots. Each range covers all trim levels and engine types for a vehicle with a typical
amount of equipment--usually an automatic transmission, air conditioning, stereo,
etc. Fully loaded vehicles may cost more. Average mileage is 12,000 miles per year. Keep
in mind that these are guidelines only. Actual selling prices vary- especially from
region to region.
Specs for this generation Ford Aerostar include everything from fuel mileage to seating capacity to options availability.
Vehicle Dimensions
| Specification | 3-door van | |
| Wheelbase, in. | 118.9 | |
| Overall Length, in. | 174.9 | |
| Overall Width, in. | 71.7 | |
| Overall Height, in. | 72.2 | |
| Curb Weight, lbs. | 3374 | |
| Cargo Volume, cu. ft. | 141.4 | |
| Standard Payload, lbs. | -- | |
| Fuel Capacity, gals. | 21.0 | |
| Seating Capacity | 7 | |
| Front Head Room, in. | 39.5 | |
| Max. Front Leg Room, in. | 41.4 | |
| Rear Head Room, in. | 38.8 | |
| Max. Rear Leg Room, in. | 39.5 | |
|
Specifications Key: NA = not available; "--" = measurement does not exist. |
||
Powertrain Options and Availability
In 1990, Aerostar's 3.0-liter V6 developed 145 horsepower and was available with either 5-speed manual shift or a 4-speed automatic transmission. The new 4.0-liter V6, rated 152 horsepower, came only with a heavy-duty 4-speed automatic transmission and was standard in 4WD models. The 4-wheel-drive system introduced in 1990 was permanently engaged. Under normal conditions, one-third of the engine's torque is sent to front wheels and two-thirds to the rear. A center differential locks in a 50-50 split if wheelspin is detected. Manual shift disappeared after '94.
| Engines | cu. in |
Horse- power | Torque | Transmission: |
Consumer Guide Observed |
| ohv V6 | 3.0 / 182 | 135-145 | 160-165 | 4-speed automatic: 17/23 | 4-speed automatic: 13.5 |
| ohv V6 | 4.0 / 244 | 152-155 | 215-230 | 4-speed automatic: 17/23 5-speed automatic: 16/22 |
4-speed automatic: 14.6 5-speed automatic: -- |
|
Specifications Key: NA = not available; "--" = measurement does not exist. |
|||||
Built In: USA
Drive Wheels: longitudinal rear-engine/rear- or all-wheel drive
Detailed safety information for this generation Ford Aerostar include detailed crash test scores from the NHTSA.
NHTSA Crash-Test Results
| Test | 1997 Aerostar |
|---|---|
| Front Impact, Driver | 4 |
| Front Impact, Passenger | 3 |
The National Highway Traffic Safety Administration (NHTSA) tests a vehicle's worthiness in front- and side-impact collisions and rates its resistance to rollovers. Front-impact crash-test numbers indicate the chance of serious injury: 5 = 10% or less; 4 = 10-20%; 3 = 20-35%; 2 = 35-45%; 1 = More than 45%. Sideimpact crash-test numbers indicate: 5 = 5% or less; 4 = 6-10%; 3 = 11-20%; 2 = 21-25%; 1 = More than 26%. Rollover resistance numbers indicate the chance for rollover when the vehicle leaves the roadway: 5 = Less than 10%; 4 = 10-20%; 3 = 20-30%; 2 = 30-40%; 1 = More than 40%.
Learn about official auto recalls, reliability issues, and vehicle problems for the 1990-1997 Ford Aerostar directly from the NHTSA and manufacturers.
NHTSA Recall History
1990 registered in specified states:
Upper portion of fuel tank can develop cracks due to extended exposure to high ambient temperatures; fuel vapor or leakage could occur.
1990:
Inability to maintain pressure in master cylinder could increase brake-pedal travel.
1990:
With quad captain's chairs, tilt-forward latch of right-hand seat in second row may release under severe frontal impact.
1990-91:
Ignition switch could short-circuit, causing smoke and possible fire.
1990-91:
When automatic transmission is in Park position, pawl does not always engage park gear.
1992 w/AWD:
Powertrain bending resonance or transfer case output shaft bushing displacement can result in structural failure leading to fluid expulsion, driveshaft separation, or loss of vehicle drive.
1992-97 w/AWD:
Structural failure of transmission and/or transfer case can occur, resulting in fluid expulsion, driveshaft separation, or loss of drive.
1992-97:
During start-up, arcing could potentially cause pitting, which, over time, might create short circuit that leads to overheating and potential fire.
1994-95:
Heat generation in wiring harness to fuel pump assembly can cause electrical short; vehicle could experience loss of power and become immobilized, fuel gauge may be erratic, and possible heat damage could lead to fire.
1995:
Underbody spare tire can contact brake lines, resulting in fracture of line.
1996:
Certification label shows incorrect rear tire inflation pressure.
1996:
When in secondary latched position, driver's door may not sustain specified load.
1997 w/3.0-liter engine:
Accelerator cable may be kinked during installation, causing the core wires to eventually fray with wire strands breaking one at a time.
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