1991 Ford Aerostar Problems & Reliability

Hey there, fellow car enthusiasts! If you’re anything like me, you probably have a soft spot for those classic rides that defined the automotive landscape of the ’90s. Today, we’re diving into a vehicle that might just bring back some nostalgic memories or perhaps a few tales of road trip adventures—the 1991 Ford Aerostar. This minivan was a staple for many families back in the day, offering a blend of space, comfort, and that unmistakable boxy charm. But like any vehicle that’s been around for a few decades, the Aerostar had its fair share of quirks and issues. So, buckle up as we explore the common problems that owners have faced and take a closer look at its overall reliability. Now, before you start reminiscing about those long drives with the windows down and the radio blasting your favorite tunes, let’s get real about what owning a 1991 Ford Aerostar entailed. While it was a reliable workhorse for many, it wasn’t without its mechanical hiccups. From transmission troubles to electrical gremlins, the Aerostar had a reputation for keeping its owners on their toes. But don’t worry, it’s not all doom and gloom! We’ll also highlight some of the reasons why this minivan still holds a special place in the hearts of many and why some folks are still cruising around in these vintage beauties today. Whether you’re considering buying one or just curious about its legacy, this post will give you the lowdown on what to expect from the 1991 Ford Aerostar.
Body Components

Parts Assessed:

Windows, power locks, manual locks, doors, trunk, tailgate, mirrors, power and manual seat controls, seat belts, sunroof, convertible top, glass defects.

Reported Problems:

N/A

Analysis:

No major problem has been reported

Parts Assessed

Brake pads, brake rotors, brake calipers, anti-lock braking system (ABS), brake lines, brake master cylinder, brake booster, parking brake, brake sensors, regenerative braking system (if applicable).

Reported Problems:

  • Engine Leaks Around Rear Crankshaft Seal and Oil Pan Gasket are Common

Analysis:

The 1991 Ford Aerostar is known to have some issues with engine leaks, particularly around the rear crankshaft seal and oil pan gasket. These leaks are pretty common and can lead to oil loss if not addressed, which might affect the overall reliability of the vehicle. If you’re considering this van, it’s a good idea to keep an eye on these areas and address any leaks promptly to maintain its performance.

Parts Assessed

Air conditioning compressor, AC condenser, AC evaporator, heater core, blower motor, automatic climate control system, refrigerant leaks, HVAC electrical components, temperature sensors, ventilation system.

Reported Problems:

  • Crossed Oxygen Sensor Wires Can Cause Poor Idle Quality/Fuel Economy

Analysis:

The 1991 Ford Aerostar has its share of quirks, and one notable issue is the potential for crossed oxygen sensor wires, which can lead to poor idle quality and reduced fuel economy. This problem can be a bit of a headache, affecting the vans overall reliability and performance. While its not a deal-breaker, its something to keep an eye on if youre considering this classic ride.

Parts Assessed

CV joints, driveshaft, axles, differential, limited-slip differential (if applicable), traction control system, electronic stability control (ESC), four-wheel-drive (4WD) components, all-wheel-drive (AWD) components, transfer case, driveline vibration.

Reported Problems:

  • Adjust AC Air Blend Door if Necessary

Analysis:

The 1991 Ford Aerostar is known for a few quirks, and one of them is the occasional need to adjust the AC air blend door. This issue can affect the temperature control inside the vehicle, but it’s generally a straightforward fix. Overall, while the Aerostar has its share of age-related problems, addressing the blend door adjustment can help maintain a comfortable ride.

Parts Assessed

Infotainment system, GPS navigation, Bluetooth connectivity, touchscreen display, phone pairing, backup camera, rear entertainment system, head-up display, instrument cluster, digital gauges.

Reported Problems:

  • Updated Differential Clutch Kit Available if Rear End Noise is Heard

Analysis:

The 1991 Ford Aerostar seems to have some issues with rear-end noise, but there’s an updated differential clutch kit available to address this problem. While this fix can help improve the situation, it’s a reminder that older vehicles like the Aerostar might require some maintenance to keep them running smoothly. Overall, if you’re hearing any strange noises, it might be worth checking out this update to ensure your ride stays reliable.

Parts Assessed

Radiator, radiator hoses, cooling fan, water pump, thermostat, antifreeze leaks, engine coolant reservoir, overheating prevention system, intercooler (if applicable).

Reported Problems:

  • Valve cover gasket may fail and leak oil onto exhaust manifold

Analysis:

The 1991 Ford Aerostar has a known issue with the valve cover gasket, which can fail and lead to oil leaking onto the exhaust manifold. This problem can cause some inconvenience and potential safety concerns if not addressed promptly. Overall, while the Aerostar has its quirks, keeping an eye on this specific issue can help maintain its reliability.

Parts Assessed

Alternator, battery, ignition switch, ignition coil, spark plugs, ignition wires, engine control module (ECM), electronic ignition system, auto stop/start function, battery cables, engine wiring harness, fuse box, relays, starter motor.

Reported Problems:

  • Sludge on Engine Throttle Body May Cause Excessive Cycling of AC Compressor Clutch

Analysis:

The 1991 Ford Aerostar seems to have a common issue with sludge buildup on the engine throttle body, which can lead to the AC compressor clutch cycling excessively. This problem might not be a deal-breaker, but it could be a bit of a hassle if you’re relying on the AC during hot weather. Overall, while the Aerostar has its quirks, regular maintenance can help keep it running smoothly.

Parts Assessed

Engine rebuilds, cylinder head, head gasket, timing chain, timing belt, camshaft, crankshaft, connecting rods, turbocharger or supercharger (if applicable), valve train, piston rings, oil control system, engine knocking, engine misfires.

Reported Problems:

  • Worn/damaged engine bearings can cause engine knocking noise

Analysis:

The 1991 Ford Aerostar is known for a few issues, with worn or damaged engine bearings being a notable problem that can lead to an annoying engine knocking noise. While this issue can affect the overall reliability of the vehicle, many owners have found that with regular maintenance and timely repairs, the Aerostar can still be a dependable ride. Just keep an ear out for any unusual sounds and address them promptly to keep things running smoothly.

Parts Assessed

Muffler, catalytic converter, exhaust manifold, heat shields, exhaust pipes, oxygen (O₂) sensors, resonator, exhaust leaks, emissions control system.

Reported Problems:

  • Loose/Worn Inner Tire Rod Ends Can Cause Steering/Tire Wear Problems

Analysis:

The 1991 Ford Aerostar has its share of issues, with loose or worn inner tire rod ends being a notable problem. This can lead to steering difficulties and uneven tire wear, which might affect the overall driving experience. While it’s a common issue in older vehicles, regular maintenance can help keep these problems in check.

Parts Assessed

Fuel pump, fuel injectors, fuel rail, fuel pressure regulator, throttle body, fuel gauge sensor, evaporative emissions system, EGR (exhaust gas recirculation) valve, charcoal canister, fuel filter, fuel tank, vapor leaks.

Reported Problems:

  • Change Power Steering Fluid to Avoid Steering Pump/Gearbox Problems

Analysis:

The 1991 Ford Aerostar is known for a few issues, and one of the key maintenance tips is to regularly change the power steering fluid. Doing this can help prevent problems with the steering pump and gearbox, which are common trouble spots in this model. Keeping up with this simple maintenance task can go a long way in maintaining the overall reliability of your Aerostar.

Flagship-One-Engine-Computer-In-Stock
Onboard & Powertrain Electronics

Parts Assessed

Cruise control, keyless entry system, push-button start, wiper motor, warning lights, power mirrors, interior lighting, exterior lighting, dashboard indicators, electronic parking brake, tire pressure monitoring system (TPMS), alarm and security system, remote engine start, heated and ventilated seats, heated steering wheel, wireless charging pad.

Reported Problems:

  • Front Brake Caliper Pins Can Corrode and Cause Brakes to Stick

Analysis:

The 1991 Ford Aerostar has a known issue with the front brake caliper pins, which can corrode over time and cause the brakes to stick. This problem can affect the overall reliability of the vehicle, as it may lead to decreased braking performance and increased wear on the brake components. Regular maintenance and inspection of the brake system can help mitigate these issues and keep the Aerostar running smoothly.

Parts Assessed

Dashboard rattles, squeaks, wind noise, door seals, weather stripping, water leaks, air leaks, excessive road noise, suspension noise, drivetrain noise, exhaust rattles, engine bay noises.

Reported Problems:

  • Battery Light Due to Damaged Alternator Wire Harness Connector

Analysis:

The 1991 Ford Aerostar has a known issue with the battery light coming on due to a damaged alternator wire harness connector. This problem can lead to charging system failures, which might leave you stranded if not addressed promptly. While it’s a specific issue, keeping an eye on the alternator connections can help maintain the van’s overall reliability.

Parts Assessed

Paint durability, clear coat protection, rust prevention, corrosion resistance, body panel alignment, door seals, window trim, plastic trim, metal finishes, fading, cracking, peeling.

Reported Problems:

  • MAP sensor failure and plugged MAP sensor hoses are common

Analysis:

No major problem has been reported

Parts Assessed

Struts, shocks, control arms, sway bars, ball joints, tie rods, wheel bearings, power steering pump, power steering fluid leaks, electronic power steering (EPS), steering rack and pinion, steering linkage, alignment issues, torsion bars, springs, air suspension (if applicable).

Reported Problems:

  • Updated electrical ignition switch available to address fire hazard

Analysis:

The 1991 Ford Aerostar had some issues with its electrical ignition switch, which posed a fire hazard. However, an updated ignition switch is now available to address this problem, improving the vehicle’s safety and reliability. With this fix, owners can feel more confident about the overall dependability of their Aerostar.

Parts Assessed

Transmission rebuild, transmission replacement, torque converter, transmission solenoids, gear selector, gear shifting, transmission control module (TCM), transmission fluid leaks, clutch (manual transmission), automatic transmission valve body, CVT (continuously variable transmission) components, dual-clutch transmission (DCT) components.

Reported Problems:

N/A

Analysis:

No major problem has been reported

Conclusion

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