1990-1997 Ford Aerostar Full Review - Consumer Guide Automotive

Our in-depth review covers everything you need to know about this generation Ford Aerostar. Get the latest news, find a local dealer, and get a free price quote for this generation Ford Aerostar.

1990-1997 Ford Aerostar Review

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.

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.

1990-1997 Ford Aerostar Road Test

Pros	Cons

Trailer-towing capability	Fuel economy

Optional AWD traction	Entry/exit

Passenger room	Ride

Cargo room (extended-length)

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.

Consumer Guide® Road Test Ratings

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:	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.

1990-1997 Ford Aerostar Reliability

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: A hammering noise and erratic temperature gauge reading is caused by a weak water pump. A revised pump is available. (1994-97)

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)

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

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.

1990-1997 Ford Aerostar Prices

Prices	Good	Average	Poor

1990
Aerostar extended	$1,100-1,500	$700-900	$100-200
Aerostar regular	$1,000-1,400	$600-800	$100

1991
Aerostar extended	$1,200-1,600	$700-1,000	$100-200
Aerostar regular	$1,100-1,500	$700-900	$100-200

1992
Aerostar extended	$1,400-1,800	$900-1,200	$200
Aerostar regular	$1,200-1,600	$700-1,000	$100-200

1993
Aerostar extended	$1,500-2,000	$1,000-1,300	$200-300
Aerostar regular	$1,300-1,700	$800-1,100	$200

1994
Aerostar extended	$1,700-2,300	$1,100-1,500	$300
Aerostar regular	$1,500-1,900	$1,000-1,200	$200

1995
Aerostar extended	$1,900-2,600	$1,300-1,800	$300-400
Aerostar regular	$1,700-2,100	$1,100-1,400	$300

1996
Aerostar extended	$2,300-3,000	$1,700-2,200	$400-600
Aerostar regular	$1,900-2,400	$1,300-1,700	$300-400

1997
Aerostar extended	$2,700-3,300	$2,000-2,500	$600-700
Aerostar regular	$2,300-2,800	$1,700-2,000	$400-500

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.

1990-1997 Ford Aerostar Specs & Safety

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	Size liters / cu. in	Horse- power	Torque	Transmission: EPA city/hgwy	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.

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%. Side-impact 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%.

Built In: USA

Drive Wheels: longitudinal rear-engine/rear- or all-wheel drive

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Also in the 1990-1997 Ford Aerostar Review:

Ford Aerostar

Ford Aerostar Road Test

Ford Aerostar Reliability

Ford Aerostar Prices

Ford Aerostar Specs & Safety

Ford Aerostar Photos

Ford Aerostar Full Review