Faults:

Cruise Control - Module replaced at 120000km.

Front Springs - one cracked near base so both were replaced at 160000km.

Air Conditioning - not sure what went wrong, but was repaired at about 190000km.

Front Boots - replaced at 200000km.

Mass Air Flow Assembly - Van was losing power so it was replaced and runs like new at 230000km.

Alternator bearing wore out twice and voltage regulator replaced once.

Ceased Coupling on one power transfer axle at about 230000km.

Tires wear around wheel rims. Probably due to the fact that the van is somewhat top heavy.

Both rear brake lights were burning out every few months one year we had it, but it mysteriously cleared up.

Rear windshield washer ceased working.

Front Hubs wore out and had to be replaced after 240000km.

Transmission Cooler was leaking and had to be replaced at about 220000km.

Engine light has come on a few times on steep hills. This might have been related to the Mass Air Flow Assembly not working properly.

General Comments:

Great utility vehicle for hauling around our 4 kids.

Handles OK.

We like the electronic AWD for traction in the winter and at the lake. However we are disappointed that Ford did not offer AWD with their Winstar and FreeStar series.

We are disappointed at our high repair bills ($3000 last year) but the van is in good shape and equivalent new AWD Ford vehicles (Expedition) are too pricey to consider.

Most people we talk to love their Aerostar, but haven't done as many km's as we have.

It's generally sluggish to respond and quite heavy.

Gas consumption is fairly high.

It gets the job done and hopefully will last a couple more years.

Faults:

Both front electric windows quit working without previous indication that something was about to malfunction.

These are the only 2 electric windows in the van.

I tried replacing the 20 amp breaker, but to no avail.

General Comments:

I very much like the van for it's roomy interior, carrying capability and reliability.

However, it does feel a bit mushy in the front as it corners.

Faults:

I bought a used 1989 aerostar by owner for 3k cash as I was in school and had kids, needed a van. It was low miles and best buy I could find. After having it 1 yr I was rear ended totaling it, thank God, I had just let the kids out for school minutes before. Knowing I was getting out of school and getting a job I decided to make that new car purchase, 95 aerostar. I looked at all vans and this was the cheapest van on market. Now...after having 2 aerostars, new & old they both had same problems! Sliding door.. what part? I don't know and no one at the service department knows either, they recommend I change all rollers and the track on the outside of the van. I was told that at two Ford service dealerships... Several hundred dolloars! Also have been told transmission and oil leaks some. How after only 63k miles? I also have had to change the power steering pump on both Aerostars. Both vans had squeaking belts even after changing all belts and pulley wheel. When vaccumning I would always find screws that came from the interior walls/door panels. Both vans rear air cond vents just fell apart as they were held together with nothing more than staples and glue. Both vans rear door shocks quit working making door very hard to lift. Ignition now turns without key. I have had for 8 yrs and only myself drove it, 63k miles and I am female who takes care of it, getting regular tuneup and oil changes.

Most of these problems happend before my warranty, but I failed to take it in. Thats why I bought new so I would not be at service center, I never could find the time to leave my van as I needed it. I will drive until it don't go anymore to make sure I get my money out of it. I will not buy another brand new car as Ford taught me a lesson. After having both new and old they did the same thing except the new one really emptied my wallet. New car insurance and interest rates. I'll buy used next time for sure. A Ford..I doubt it!