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1997 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1997 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1997 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1997 Ford Aerostar

Component

Vehicle Speed Control:Cables

Consequence of Defect

vehicle description: minivans equipped with 3.0l engines. an accelerator cable was kinked during installation, causing the core wires to eventually fray.

Corrective Action

this could increase the friction in the cable, causing the throttle to be slow to return to idle. this condition could result in a stuck throttle.

Recall Notes

dealers will install a new accelerator cable.

1997 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1996 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1996 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1996 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1996 Ford Aerostar

Component

Equipment:Other:Labels

Consequence of Defect

the certification labels on the involved vehicles has incorrect rear tire inflation pressure designations. this does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."

Corrective Action

incorrect inflation pressures could cause premature wear of the rear tires. .

Recall Notes

owners will be provided with correct certification labels and instructions for installing these labels. dealers can install this label if the owner so desires.

1996 Ford Aerostar

Component

Latches/Locks/Linkages:Doors:Latch

Consequence of Defect

when in the secondary latched position, the driver door latches may open when subjected to transverse loads less than that specified in fmvss no. 206, "door locks and door retention components."

Corrective Action

the driver's door, when closed only to the secondary latched position, may not sustain a 1,000 pound transverse load.

Recall Notes

dealers will inspect and, if necessary, replace the driver door latch.

1996 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1995 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1995 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1995 Ford Aerostar

Component

Equipment:Mechanical:Carrier/Rack

Consequence of Defect

the spare tire supplied with the vehicle can contact the brake lines on the rear axle if it is mounted in the underbody spare tire carrier. such contact could result in fracture of a rear brake line.

Corrective Action

this can result in reduced vehicle brake capability.

Recall Notes

dealers will install a lower profile mini-spare tire on the existing mini-spare wheel. the new tire will allow the mini-spare to be installed with appropriate clearances in the underbody spare tire carrier.

1995 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1995 Ford Aerostar

Component

Equipment:Other:Labels

Consequence of Defect

the certification label on these vehicles have incorrect rear tire sizes listed. p215/70r14sl should be p215/75r14sl. this does not comply with fmvss no. 120, "tire selection and rims for motor vehicles other than passenger cars."

Corrective Action

consequence of non-compliance: the incorrectly sized rear tire would not have sufficient load capacity for the vehicle's specified gross axle weight rating, increasing the potential for premature tire failure.

Recall Notes

owners will be mailed a supplementary label containing the correct rear tire information and instructions for installing the label on their vehicles. if owners prefer, their dealer can install the label for them.

1995 Ford Aerostar

Component

Electrical System:Wiring:Front Underhood

Consequence of Defect

vehicle description: mini vans. heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. the vehicle could experience a loss of power and become immobilized and the fuel gauge may be erratic.

Corrective Action

heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. the short circuit could also have the potential for a vehicle fire.

Recall Notes

dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.

1995 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1994 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1994 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1994 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1994 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1994 Ford Aerostar

Component

Electrical System:Wiring:Front Underhood

Consequence of Defect

vehicle description: mini vans. heat generation in the wiring harness to the fuel pump/sender assembly can cause an electrical short. the vehicle could experience a loss of power and become immobilized and the fuel gauge may be erratic.

Corrective Action

heat damage, including melting or charring of the fuel pump and sender assembly wire harness and associated wiring harnesses can also result. the short circuit could also have the potential for a vehicle fire.

Recall Notes

dealers will install a fused jumper harness in the fuel pump ground circuit that will be installed at the fuel pump inertia shut-off switch.

1994 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1993 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1993 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1993 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1993 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1992 Ford Aerostar

Component

Service Brakes, Hydraulic

Consequence of Defect

certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006 (date codes 0529 through 0602) are subject to this recall. when subject to very cold temperatures, an internal seal in the master cylinder could lose flexibility and may cause brake fluid to leak.

Corrective Action

loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.

Recall Notes

affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.

1992 Ford Aerostar

Component

Electrical System:Ignition:Switch

Consequence of Defect

vehicle description: mini vans. these vehicles were produced with a higher than specified electrical load through the accessory power feed circuit. the potential for contact between the b2 (battery), a2 (accessory), and p1 (proof) circuits can occur, creating a short circuit, allowing current to flow through the ground wire.

Corrective Action

this can cause over heating and the potential for a vehicle fire.

Recall Notes

dealers will install a jumper harness with a relay which will re-route and activate all a2 accessories through the relay.

1992 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1992 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. (this includes all 1992 awd aerostars not previously included in safety recall 97v-204/97s83). these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1992 Ford Aerostar

Component

Power Train:Transfer Case (4-Wheel Drive)

Consequence of Defect

vehicle description: all wheel drive passenger minivans. these vehicles can develop powertrain bending resonance or transfer case output shaft bushing displacement. the powertrain bending resonance or the output shaft bushing displacement can result in structural failure of the transmission and/or transfer case. fluid explusion, driveshaft separation or loss of vehicle drive can result.

Corrective Action

this condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.

Recall Notes

dealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.

1991 Ford Aerostar

Component

Power Train:Automatic Transmission

Consequence of Defect

when the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.

Corrective Action

driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. this can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. all of these conditions canresult in a vehicle accident.

Recall Notes

repair the transmission with a new park pawl.

1991 Ford Aerostar

Component

Seat Belts:Front:Anchorage

Consequence of Defect

seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.

Corrective Action

vehicles would not comply with fmvss 210.

Recall Notes

replace noncomplying sofa bar with bar that meets requirements.

1991 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1991 Ford Aerostar

Component

Electrical System:Ignition

Consequence of Defect

the ignition switch could experience an internal short circuit.

Corrective Action

this condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.

Recall Notes

dealers will replace the ignition switch.

1990 Ford Aerostar

Component

Power Train:Automatic Transmission

Consequence of Defect

when the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.

Corrective Action

driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. this can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. all of these conditions canresult in a vehicle accident.

Recall Notes

repair the transmission with a new park pawl.

1990 Ford Aerostar

Component

Seat Belts:Front:Anchorage

Consequence of Defect

seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.

Corrective Action

vehicles would not comply with fmvss 210.

Recall Notes

replace noncomplying sofa bar with bar that meets requirements.

1990 Ford Aerostar

Component

Seats:Front Assembly:Recliner

Consequence of Defect

the second row right hand seat assembly has a tilt forward function. a latch retains the seat in the normal ride postion, and this latch may release under severe frontal impact conditions, allowing the seat to pivot forward.

Corrective Action

in the event of vehicle accident, the seat could pivotforward, increasing the risk of injury to the occupant.

Recall Notes

replace seat pawl assembly with a revised design assembly.

1990 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1990 Ford Aerostar

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. territories covered by the federal statutes. the upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. fuel vapor or leakage could occur at these cracks.

Corrective Action

if an ignition source is present, a fire could result.

Recall Notes

dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. this coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.

1990 Ford Aerostar

Component

Service Brakes, Hydraulic:Foundation Components:Master Cylinder

Consequence of Defect

inability to maintain pressure in the secondary system of the master cylinder (controls braking of rear wheels) could increase brake pedal travel and reduce brake performance at temperatures less than 40 degrees.

Corrective Action

this would cause reduced braking effectiveness andincreased stopping distance that could result in a crash or collision.

Recall Notes

install new design master cylinder incorporating a redesigned seal.

1990 Ford Aerostar

Component

Electrical System:Ignition

Consequence of Defect

the ignition switch could experience an internal short circuit.

Corrective Action

this condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.

Recall Notes

dealers will replace the ignition switch.

1989 Ford Aerostar

Component

Power Train:Automatic Transmission

Consequence of Defect

when the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.

Corrective Action

driver may believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. this can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. all of these conditions canresult in a vehicle accident.

Recall Notes

repair the transmission with a new park pawl.

1989 Ford Aerostar

Component

Seat Belts:Front:Anchorage

Consequence of Defect

seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.

Corrective Action

vehicles would not comply with fmvss 210.

Recall Notes

replace noncomplying sofa bar with bar that meets requirements.

1989 Ford Aerostar

Component

Seats:Front Assembly:Recliner

Consequence of Defect

the second row right hand seat assembly has a tilt forward function. a latch retains the seat in the normal ride postion, and this latch may release under severe frontal impact conditions, allowing the seat to pivot forward.

Corrective Action

in the event of vehicle accident, the seat could pivotforward, increasing the risk of injury to the occupant.

Recall Notes

replace seat pawl assembly with a revised design assembly.

1989 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1989 Ford Aerostar

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. territories covered by the federal statutes. the upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. fuel vapor or leakage could occur at these cracks.

Corrective Action

if an ignition source is present, a fire could result.

Recall Notes

dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. this coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.

1989 Ford Aerostar

Component

Electrical System:Ignition

Consequence of Defect

the ignition switch could experience an internal short circuit.

Corrective Action

this condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.

Recall Notes

dealers will replace the ignition switch.

1988 Ford Aerostar

Component

Structure:Body:Hatchback/Liftgate:Support Device

Consequence of Defect

some liftgate gas cylinder-to-body attachment ball studs may fracture in either the open or closed position.

Corrective Action

if a ball stud fractures, the liftgate will not remain inthe open position. bodily injury could result if the liftgate drops whilesomeone is under it.

Recall Notes

replace the gas cylinder-to-body attachment ball studs.

1988 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1988 Ford Aerostar

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: mini vans originally sold or currently registered in the following states: alabama, arizona, arkansas, california (10 southern counties of los angeles, orange, san bernadino, san diego, riverside, ventura, santa barbara, san luis obispo, imperial, and kern), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county), oklahoma, south carolina, and texas, and in the u.s. territories covered by the federal statutes. the upper portion of the fuel tank can develop small cracks due to extended exposure to very high ambient temperatures. fuel vapor or leakage could occur at these cracks.

Corrective Action

if an ignition source is present, a fire could result.

Recall Notes

dealers will replace the fuel tank, regardless of mileage, through march 31, 2002. this coverage will only be for structural cracks at the top of the tank and will not include other damage caused by an accident or road debris.

1988 Ford Aerostar

Component

Electrical System:Wiring

Consequence of Defect

vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.

Corrective Action

should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. the possibility exists for a fire if thewires are exposed to combustible materials.

Recall Notes

installation of a relay with wires of gauge adequate to protect the circuit.

1988 Ford Aerostar

Component

Electrical System:Ignition

Consequence of Defect

the ignition switch could experience an internal short circuit.

Corrective Action

this condition could cause overheating, smoke, and possibly fire in the steering column area of the vehicle.

Recall Notes

dealers will replace the ignition switch.

1987 Ford Aerostar

Component

Structure:Body:Hatchback/Liftgate:Support Device

Consequence of Defect

some liftgate gas cylinder-to-body attachment ball studs may fracture in either the open or closed position.

Corrective Action

if a ball stud fractures, the liftgate will not remain inthe open position. bodily injury could result if the liftgate drops whilesomeone is under it.

Recall Notes

replace the gas cylinder-to-body attachment ball studs.

1987 Ford Aerostar

Component

Seat Belts:Front:Anchorage

Consequence of Defect

vans were produced without plastic cover designed to cover outboard seat back pivot hinge allowing webbing of front passenger-side safety belts to become abraded or cut due to contact with exposed hinge.

Corrective Action

damage to belt webbing could weaken belts to point offailure increasing risk of injury in an accident or a sudden stop.

Recall Notes

install plastic pivot cover; replace belts as necessary.

1987 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1987 Ford Aerostar

Component

Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

Consequence of Defect

spring lock fuel line coupling may not be properly engaged.

Corrective Action

coupling could disengage due to fuel pressure,vibration, and engine movements; this would cause loss of fuel which, inpresence of an ignition source, creates a fire risk.

Recall Notes

install retainer clips over the couplings to prevent coupling separation and fuel leakage.

1987 Ford Aerostar

Component

Electrical System:Wiring

Consequence of Defect

vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.

Corrective Action

should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. the possibility exists for a fire if thewires are exposed to combustible materials.

Recall Notes

installation of a relay with wires of gauge adequate to protect the circuit.

1986 Ford Aerostar

Component

Seat Belts:Front:Anchorage

Consequence of Defect

vans were produced without plastic cover designed to cover outboard seat back pivot hinge allowing webbing of front passenger-side safety belts to become abraded or cut due to contact with exposed hinge.

Corrective Action

damage to belt webbing could weaken belts to point offailure increasing risk of injury in an accident or a sudden stop.

Recall Notes

install plastic pivot cover; replace belts as necessary.

1986 Ford Aerostar

Component

Seats

Consequence of Defect

wiring for the power lumbar seat system was routed directly beneath the seat cushion springs and may be abraded by the springs.

Corrective Action

this could result in a short circuit which may createsufficient heat to start a fire in the seat cushion pad and/or trim cover.

Recall Notes

install a fuse within the power lumbar electrical circuit.

1986 Ford Aerostar

Component

Service Brakes, Air:Disc:Rotor

Consequence of Defect

equipment description: aftermarket brake rotors for use on certain ford and mazda trucks. cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole.

Corrective Action

loss of braking can result.

Recall Notes

aimco will reimburse consumers/installers for the cost of replacement rotors and installation. consumers are requested to return to the location where the rotors were originally purchased/installed for replacement.

1986 Ford Aerostar

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

fuel tanks may have been scored or penetrated when floor pan mounting holes for the partitions were drilled. consequence of defect: fuel leakage may occur and in the presence of an ignition source, the potential for a fire would exist.

Corrective Action

Recall Notes

replace fuel tanks as necessary.

1986 Ford Aerostar

Component

Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap

Consequence of Defect

insufficient interference fit between fuel tank filler pipe and grommet could result in an inadequate seal which could allow fuel to seep from the joint.

Corrective Action

in the presence of an ignition source, fuel leakage could result in a fire.

Recall Notes

install a revised design grommet.

1986 Ford Aerostar

Component

Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

Consequence of Defect

spring lock fuel line coupling may not be properly engaged.

Corrective Action

coupling could disengage due to fuel pressure,vibration, and engine movements; this would cause loss of fuel which, inpresence of an ignition source, creates a fire risk.

Recall Notes

install retainer clips over the couplings to prevent coupling separation and fuel leakage.

1986 Ford Aerostar

Component

Electrical System:Wiring

Consequence of Defect

vehicles equipped with trailer tow package have a trailer taillight relay assembly that contains wires of smaller gauge than the fuse link which protects the circuit.

Corrective Action

should a short circuit occur in the wiring within therelay or if water intrusion occurs the smaller gauge wire in the relay willfunction as a fuse link and overheat. the possibility exists for a fire if thewires are exposed to combustible materials.

Recall Notes

installation of a relay with wires of gauge adequate to protect the circuit.

1986 Ford Aerostar

Component

Suspension:Rear:Springs:Leaf Spring Assembly

Consequence of Defect

there may be inadequate welding in some underbody structural areas, including those at the rear suspension attachments, which may cause it to separate. consequence of defect: if rear suspension attachments should separate from the underbody during vehicle use, the axle could shift during acceleration or braking and may adversely affect the steering control which may lead to an accident.

Corrective Action

Recall Notes

reinforce suspect weld locations and modify to prevent weld failure.

1986 Ford Aerostar

Component

Fuel System, Gasoline:Delivery:Fuel Pump

Consequence of Defect

certain federal-mogul aftermarket fuel pumps sold under the brand names of carter, accuflow, napa, truflow, parts depo, and parts master, shipped between august 2006 and july 2007 for use on the vehicles listed above. the fuel pump diaphragm in certain production runs may have been improperly installed or inadequately tested which may cause the fuel pump to leak.

Corrective Action

a leaking fuel pump could create a vehicle fire hazard.

Recall Notes

federal-mogul will notify owners and replace the defective fuel pumps free of charge. the recall is expected to begin during september 2007. owners can contact federal-mogul at 248-354-7700.