Ford Aerostar 1992 - Service brakes - car safety information, failing parts, recalls, bulletins, complaints

Ford Aerostar 1992

Recalls
Technical Service Bulletins
Defect investigations
Consumer Complaints

Recalls

Campaign	Manufacturer	Type	# of units affected	Date Owner notified Mfg	Recall Initiated by	Manufacturers of recalled vehicles/products	Report Recieved Date	Record Creation Date
SERVICE BRAKES, AIR - DISC - ROTOR
98E010000	AIMCO PRODUCTS INC.	E (Equipment)	23500	04/15/1998	MFR	FORD MOTOR COMPANY	04/08/1998	04/09/1998
Defect Summary	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.
Consequence Summary	Loss of braking can result.
Corrective Summary	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.
Notes	Owner notification is expected to begin during april 1998.owners who do not receive the free rotors within a reasonable time should contact aimco at 815-759-7935.also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
SERVICE BRAKES, HYDRAULIC
06E022000	BRAKE PARTS, INC.	E (Equipment)	7440	03/20/2006	MFR	FORD MOTOR COMPANY	03/13/2006	03/13/2006
Defect Summary	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.
Consequence Summary	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.
Corrective Summary	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.
Notes	This recall only pertains to aftermarket napa, raybestos, ac delco, aimco, carquest, and bendix brake hydraulic master cylinders and has no relation to any original equipment installed on daimlerchrysler or ford vehicles.customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

Bulletins

Bulletin	Bulletin date	Item no.	Summary	Added
SERVICE BRAKES, HYDRAULIC - ANTILOCK
95212	10/01/1995	46478	The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. if petroleum-based grease is used to lubricate any par	04/25/1996
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS
985A52	03/18/1998	613023	This bulletin contains service tips when servicing any brake related roughness / pull concerns. *tt	06/16/2000
962617	12/16/1996	51002	Brakes - brake service - service tips. *tw	06/17/1997
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC
985A13	03/18/1998	601012	The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable. *yc	06/17/1998
SERVICE BRAKES, HYDRAULIC - SWITCHES - BRAKE LIGHT
02176	09/02/2002	10008580	Lamp-brake-invadvertent disabling of brake shift interlock. *mj	08/05/2004

Investigations

NHTSA ID	Manufacturer	Date open	Date close	Subject
SERVICE BRAKES, HYDRAULIC
PE99035	FORD MOTOR COMPANY	05/12/1999	09/23/1999	FRONT BRAKE HOSE
	Alleged that a front brake hose ruptures or fails at the interface between the rubber hose and the brass fitting

Consumer Complaints

Fail date	miles	occurences	Purchase date
SERVICE BRAKES, AIR - ANTILOCK
02/01/1999		4	05/01/1992
	No summary
SERVICE BRAKES, HYDRAULIC - ANTILOCK
01/05/2001		20	04/01/1992
	On friday, january 5, 2001, i was coming home on the 101 freeway when suddenly a truck cut in front of me. all i could do was slam on my brakes and i could feel something was pulling the car back, when i pushed the gas pedal the car had a hard time accelerating. this really scared me because i was on the 101 and 23 intersection. i had no way of pulling to the side of the road. i could smell something was burning really bad because i had to roll down my windows. i looked at the dash board and everything was normal. when i got off the freeway i called my husband and he smelled the brakes right away. when he touched the back tires it was really hot. he drove it home about one miles from our house and he only used the emergency brakes. because he thought there was something wrong with the rear brakes. at home all the brake fluid drained out from the rear cylinders. the next day we took it to the mechanic who replaced the cylinders and the brake shoes. but he thought since i used the emergency brake and forgot to release it that caused the damage to the rear brake. on the same day my husband was driving the van and he had to slam on the brakes and it stayed locked, he touched the brake pedal again and the brake was fine again. we went back to the garage and check everything out but they found nothing wrong because all the lights were functioning properly. so my husband decided to take the fuse out from the abs brake. the problem disappeard. we came to the conclusion that when the abs do the self-diagnostics, it doesn't detect a fault in the system and could not turn off the system so the regular brake should function properly. i took it to ford on monday, january 15, 2001 and they found the problem in the abs system. they replaced the rabs valve. the brake is good again. when i asked why rabs lights don't give me any warning and shut the system down, he said sometimes the light goes on sometimes it doesn't. *ak
04/06/2000
	While driving on the highway all of sudden the rear abs warning light intermittently came on. didn't contact the dealer or manufacturer. *ak
10/16/1998
	When applying the brakes during a normal stopping condition, the rear abs locked up, and the truck did a 180 degree turn, causing a crash. this happened on dry/ normal road condtions. the vehicle was totalled. *ak
05/12/1993
	When driving at 40 mph and coming to a stop sign, consumer applied the brakes, and the brake's were hard. abs system kicked in and locked up causing vehicle to go straight through a stop sign which could have resulted in a collision. ak yc
07/22/1999
	Brakes smell like smoke, and they chatter and lose power. *ak
		18
	Abs system grabs on damp/wet days causing wheels to slide at low/med speeds resulting in vehicle sliding into ditch on a snowy day. nlm
04/23/1999
	When driving and trying to use the turning signal it doesn't work and the back up lamp isn't working either. also, heater malfunctioned, and the red brake light and the yellow anti- brake light stays on. consumer had just brought the vehicle back from repair shop for a recall service, and the consumer is having all of types of problems with vehicle. *ak

	When applying the abs brakes the front wheels grab and vibrate, cause unknown. please give any further details. *ak
03/31/1998
	Driver's power window malfunctioned. in addition, transmission failed/abs light intermittently comes on/master cylinder failed, causing an accident/air conditioning compressor failed/tie rods replaced/tail lights repeated ly replaced/ignition switch failed, causing a fire/repeated engine oil leaks and catalytic converter replaced.
10/04/1997			07/23/1993
	Air conditioning compressor malfunctioned. in addition, noisy abs brakes/defective front/rear cv joints/premature wear of front brake pads and rotors/electric door locks malfunctioned/lower ball joint noise/ radiator hose failure and premature distributor/cap/rotor wear. *ak
09/13/1997		1
	Owner was driving and applied the brakes van didn't stop. she then applied them again and the van then came to a stop. ak consumer looked under vehicle and noticed hydraulic brake hose hanging from tire, it came off at metal connection to brake line, hose is intact, there are no rips, holes or tears, consumer replaced brake hose, however the front left hose came off in the exact same point. slc
11/16/1996		0
	Applied brakes(abs) at 30 -35 mph vehicle started to slow down but, didn't stop due to this failure the vehicle rear ended another vehicle. please describe details. *ak

	During a cold night with a temperature of below 32 degrees, rear anti-lock brakes freeze up and stay locked up through next morning hours. have to wait to thaw. *ak

	Abs system brakes lock up in wet weather. please describe. *ak
10/12/1995
	Abs, while driving the left brake pads fell out while driving. tt
05/03/1995
	When brakes get wet or cold, abs malfunction, resulting in lockup and an accident. tt

	Equipped w/tow package & abs brakes; upon steady application or down hill, brake pedal goes to floor. please describe details. tt
07/01/1995
	Abs, brake failure, continue wear of disc rotors and pads, in front and rear, replace 7 times. tt
05/23/1995
	Frontal collision impact 12:00 position 25 mph, brake failure abs lockup on wet surface airbag on drivers side partically deployed, also lap/shoulder belt fail.
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS
		1
	Brakes failed.*et
01/01/1996
	When driving at any speed the brakes are working intermittently which cause a problem. vehicle has been in repair shop for different reasons, as well as for the brakes. dealer can't determine the problem. *ak
01/11/1999
	There is a popping noise coming from the brakes, causing fluid to flow out from the brakes. also, consumer lost control of the steering due to the steering wheel locking up. consumer left vehicle at the dealer. *ak
01/12/1996
	While driving at 50 mph the transmision started to go out, causing the consumer to lose power. also, when applying the brakes the brakes went straight to the floorboard. vehicle has been into the shop five times for the brakes, and they can't determine the problem. *ak
11/06/1998		1
	The consumer has been experiencing problems with airbags and brakes. the consumer was involved in a front collision in whichbrakes failed to operate. when applied brakes, pedal went to the floorboard. in addition, the airbags failed to deploy. the manufacturer has been contacted.*ak
		1
	Flexible brake hose split causing brake failure.design of the brakes system does not contain a dual brake system which would be a back up when failure occurs.
09/02/1998
	Driving about 3 to 5 mph in the parking lot and upon applying brake's, they fell off and the fluid bled out on one pump. the brake pedal went straight to the floor. consumer had to use the emergency brakes, and put the vehicle into park to stop the vehicle. contacted dealer. *ak
09/13/1997		1
	Owner was driving and applied the brakes van didn't stop. she then applied them again and the van then came to a stop. ak consumer looked under vehicle and noticed hydraulic brake hose hanging from tire, it came off at metal connection to brake line, hose is intact, there are no rips, holes or tears, consumer replaced brake hose, however the front left hose came off in the exact same point. slc
12/20/1994		0
	Right rear wheel locked up, causing vehicle to skid into intersection. *skd
02/01/1995
	Braking system failure, wet conditions will make brake extremely sensative. tt
10/21/1994
	Abs: all brake parts have been replaced 2 times within 2 years, including master cylinder; pedal goes to floor; extended stopping; caused accident. tt
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC
		1	09/29/1994
	Vehicle traps dirt between the dust plates behind the disc brakes causing the brakes to fade and make noise.
10/04/1997			07/23/1993
	Air conditioning compressor malfunctioned. in addition, noisy abs brakes/defective front/rear cv joints/premature wear of front brake pads and rotors/electric door locks malfunctioned/lower ball joint noise/ radiator hose failure and premature distributor/cap/rotor wear. *ak
07/12/1992
	Vehicle developed chattering noise and the brakes disintegrated. *ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - CALIPER
01/01/1995
	The 3rd time in 20,000 miles and they had to replace rotors, calipers, and shoes. please describe. *ak
10/15/1993		1
	Replaced front calipers. *ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - PADS
06/09/1992
	Failure of the front brake shoes and padd, the pads are wearing to often, the front brakes also locks up when driving. *ak
10/20/1995		4	04/01/1992
	Brake pads on vehicle wear out excessively, need replacement every 4k to 5k miles. tt rotors are continually warping, brakes pads crystalizing, causing vibration and noises. *slc
10/12/1995
	Abs, while driving the left brake pads fell out while driving. tt
07/01/1995
	Abs, brake failure, continue wear of disc rotors and pads, in front and rear, replace 7 times. tt
01/01/1995
	The 3rd time in 20,000 miles and they had to replace rotors, calipers, and shoes. please describe. *ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - ROTOR
10/14/1999
	When consumer applies foot to the gas pedal, brakes move the vechicle slowly. consumer took the vehicle to the dearlership, and mechanic told him that he had glaze on brake rotors. *ak
04/23/1999
	When driving and trying to use the turning signal it doesn't work and the back up lamp isn't working either. also, heater malfunctioned, and the red brake light and the yellow anti- brake light stays on. consumer had just brought the vehicle back from repair shop for a recall service, and the consumer is having all of types of problems with vehicle. *ak
08/01/1997		5	11/01/1992
	Wiring harness ignited by spontaneous combustion, resulting in a fire/brake rotors continuously warp, and air conditioner failed twice.
		3	03/01/1992
	Front brake rotors warped.
10/20/1995		4	04/01/1992
	Brake pads on vehicle wear out excessively, need replacement every 4k to 5k miles. tt rotors are continually warping, brakes pads crystalizing, causing vibration and noises. *slc

	Engine light keeps coming on took to dealer couldn't find problem replaced the rotor and pads on two occasion . tt
07/01/1995
	Abs, brake failure, continue wear of disc rotors and pads, in front and rear, replace 7 times. tt
01/01/1995
	The 3rd time in 20,000 miles and they had to replace rotors, calipers, and shoes. please describe. *ak
04/27/1995
	Abs, front brakes make vibration, turn rotors in for repair 6 times. tt
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - HOSES, LINES/PIPING, AND FITTINGS
01/20/2005	68000	1
	Owner was going at approximately 45 mph. owner applied the brakes and the brakes went to the floor. owner says that the front right brake hose line popped right off. causing the vehicle to lose all brake pressure preventing the vehicle from stopping. provide further details. *nm
07/02/2001		1
	While backing out of a parking space and depressing brake pedal, pedal traveled to floorboard. consumer noticed loss of braking power . vehicle was towed home when consumer noticed that brake hose was broken.ak consumer states the front flexible brake hose has a heavy rubber boot covering the upper swagged fitting, this boot entraps salt and water causing the fitting to corrode severely and is hidden under the boot, consumer replaced the opposite line because it was rusted on the same fitting. slc
08/25/2000		1	07/01/1999
	Right side front connector to brake flexible line broke off. dealer said left side was ready to go and both were replaced. the major problem i see was that i had no braking save for the emergency brake. the rear brakes failed also and independent mechanics have told me that i should have only lost the front brakes due to the redundant brake cylinder system. however, the ford service manager said this was normal if you lost one line. if that's the case, this is a severe safety hazard that should be addressed. i contacted ford motor co. for technical advice and to report a possible flaw. the service manager had even said that the protection for the brake fittings had been improperly installed upon the vehicle at the factory. *ak
04/04/1999
	As driver was applying brakes, to shift from park to drive or reverse, brake pedal went to the floorboard. also, brake hose line separated from metal that was connected to the brake line due to rust. brake hose has been replaced. please provide any further information. *ak
11/01/1998		2	06/01/1994
	Consumer would like to report brake line hoses cracking and leaking. believed this is a result of a manufacturer's design flaw. nhtsa should look into this matter. ak ml

	Rubber portion of the brake hose separated from metal fitting that connects to the brake line, causing a loss of braking power, resulting in a collision. *ak
05/01/1998		1
	In the last year both of the front brake lines have ruptured, leaving us with no brakes. the ruptures occurred at low speeds ar when putting the van into drive. only this prevented us from the potential of serious injury. ford tells me that there has been on recall on this and i am left wondering if this will continue to occur. mechanics that fixd the car both said this was a ford defect because they have never seen this type of failure before and this was abnormal. my wife will no longer drive the car.....what recourse do we have and is this a problem with these vehicles? *ak
01/17/1999
	While driving the van about 35 mph driver applied the brakes and there was 90% brake loss. driver was able to avoid a crash. this was due to corrosion of the brake line. the brake line has been replaced by the ford dealership. please describe any further details.
02/03/1998		1
	Flexible brake hose to the right from wheel split, causing brakes to fail, preventing vehicle from stopping.
12/15/1997		1
	Separation of the flexible portion of the brake hose from the metal attaching caused by corrosion which has built up as a result of the design of this brake hose resulting in brake failure and a collision.
09/02/1998		1	07/14/1992
	Flexible brake line coupling separated from rotor causing loss of fluid and brakes.
08/05/1997		1
	Abs, front brake line rotted/corroded/ rusted; brakes collapsed, disintegrated. brake lines replaced. *ak
05/26/1997
	While driving the vehicle and applying the brakes the pedal went down to floor. upon checking the vehicle, discovered the brake fluid leaked because the hose came apart from the fitting. owner will repair the vehicle. *ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - MASTER CYLINDER
08/25/2000		1	07/01/1999
	Right side front connector to brake flexible line broke off. dealer said left side was ready to go and both were replaced. the major problem i see was that i had no braking save for the emergency brake. the rear brakes failed also and independent mechanics have told me that i should have only lost the front brakes due to the redundant brake cylinder system. however, the ford service manager said this was normal if you lost one line. if that's the case, this is a severe safety hazard that should be addressed. i contacted ford motor co. for technical advice and to report a possible flaw. the service manager had even said that the protection for the brake fittings had been improperly installed upon the vehicle at the factory. *ak
03/31/1998
	Driver's power window malfunctioned. in addition, transmission failed/abs light intermittently comes on/master cylinder failed, causing an accident/air conditioning compressor failed/tie rods replaced/tail lights repeated ly replaced/ignition switch failed, causing a fire/repeated engine oil leaks and catalytic converter replaced.