Faults:

#4 spark plug keeps fouling out at 200,000 miles. Replace it every 5,000 miles, and it just keeps going.

Rockers panels are starting to rust through.

Front wheel bearing went out at 210,000 miles.

Transmission failed at 240,000 miles; just last month.

It is now in the junk yard, but what a great Aerostar.

General Comments:

Bought this for a company car. It has been up to the AFT trade show in Fargo, ND about 24 times and in in blizzard conditions. The AWD drive saved my life a couple times for sure on those trips. Have hauled heavy loads to trade shows regularly for years with this thing, and it just kept going strong until the last 3 years.

Unlike my previous Chevy Astro van, this Aerostar never had any broken door handles, or window switches, or windshield wiper motor failures.. not ever. Pretty solid vehicle overall. Good transmission, good engine. Great brakes. Excellent cruise control.

The only thing I didn't like about it was the small diameter wheels. And the rust.

Ford builds some incredibly reliable stuff, that can take abuse for years.

Faults:

The accelerator sensor went out at 75,000 miles.

The fuel pump went out at 102,000 miles.

The alternator went out at 147,000 miles.

The sliding door track broke 3 times.

The a/c stopped working at 126,000 miles.

General Comments:

This was a great van. It is too bad they quit making them in 1997. Are family loved it.

We took it on many trips and averaged 28 mpg. The 3.0 motor is not the fastest but it got the job done.

It was a very roomy van unlike many others. It had good luggage space also.

We like it so much we bought another one!

Faults:

Just the usual.

Actually, if properly maintained not much trouble between 120000 and 200000 in these Vans.

They burn through brakes, even when babied.

Check engine light randomly illuminates, no codes to show true problem.

If wise, NEVER replace an individual tire on the AWD, do all 4 or none. Trust me, it'll eat the transfer case over time.

Plastic interior panels are poorly fastened. (Big deal, eh?)

General Comments:

I love these things! Yes they have their issues. I've owned 5 Aerostars and have dealt with it all. My 300E has troubles as well- it's a car folks.

I use the Aerostars for work, so they run loaded daily. The AWD is wonderful in mountainous terrain; add studded tread on the icy stuff and go anywhere clearance allows.

Compared to the GM offerings, the Aerostars' are about half the price on the used market. Half the vehicle? Doubt it.

For some reason the earlier model AWD's performed better in the white stuff. Anybody know why?

Oh, by the way, the 2WD is horrible in the snow!

4.0 litre seems to be a fine build. The last AWD I had was a 90. Drive train done at 265K, though engine ran fantastic, burned no oil, and typical mileage avg. 18. Kudos Ford.

The 95 I'm currently driving gets about 15.5.??

I should mention, ladder rack and ladders atop, as well as fair amount of weight inside.

If your planning on removing/installing rear seats on regular basis, eat your wheaties or be on good terms with your neighbors- you'll need 'em!

Faults:

At 180 000 kilometers, I replaced the power steering hose.

At 182 000 kilometers, I had to replace the head gasket due to a spark plug being very badly seized. I also replaced the rear brake shoes.

At 187 000 kilometers, I replaced the engine.

At 188 000 kilometers, I replaced the daytime running light module.

At 188 000 kilometers, I also had to replace the starter.

At 195 000 kilometers, I replaced the power steering hose again.

At 202 000 kilometers, I replaced the entire exhaust system and the CV boot.

At 205 000 kilometers, I needed wheel cylinders, pads, rotors and shoes.

At 207 000 kilometers, I replaced the rear shocks.

At 210 000 kilometers, I replaced the shifting belt.

The seat belt mechanism at the back is faulty.

The rear windshield wiper motor does not work.

The sliding door does not slide well at all. I continually have to adjust it.

The bottom rocker panels are rusting.

General Comments:

I am hoping that few people will be buying this vehicle as it is now 9 years old.

I have had nothing, but trouble with my Ford Aerostar. At this point, I have put too much money into my Aerostar. I paid 7000 for it and have put approximately 8000 into it.

Granted the mileage is quite high, but I am disappointed by the continual need for repairs.