Recalls

CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
97V204000FORD MOTOR COMPANYfrom 01/31/1992 to 01/20/1997V (Vehicle)7500002/16/1998MFRFORD MOTOR COMPANY11/13/199711/20/1997
Defect SummaryVehicle 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.
Consequence SummaryThis condition can cause a loss of vehicle control, and, if the expelled fluid contacts the exhaust system, a vehicle fire could occur.
Corrective SummaryDealers will install a new transfer case rear output shaft bushing and an aluminum driveshaft will be installed.
NotesOwner notification is expected to begin february 16,1998.owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.also contact the national highway traffic safety administration's auto safety hotline at 1-800-424-9393.

Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
POWER TRAIN - AUTOMATIC TRANSMISSION
9915207/26/1999608431Information on the new flush and fill tool available through rotunda. *tt01/05/2001
001501/10/2000612203Information regarding the new transmission cooler flusher- service tip. *mjs06/06/2000
98308002/26/1998607372Information regarding transfer case rear housing and driveshaft replacement. *tt09/21/1999
9811201/19/1998605573Subject regarding a new service center support that uses a thrust bearing (#3 and #4) in place of thrust washers has been released. *tt07/12/1999
988804/27/1998601238Information on a new transmission fluid usage chart. *yc07/10/1998
9751103/03/199751945Fluid- transmission fluid usage charts. *jd07/17/1997
BC135095090609/01/199545756High altitude transmission available. *tw04/25/1996
95101205/01/199542097Transfer case may leak fluid from the case vent tube. *tw11/01/1995
POWER TRAIN - AUTOMATIC TRANSMISSION - COOLING UNIT AND LINES
0314807/21/200310003748New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt10/29/2003
00231011/13/2000616522Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. *tt03/05/2001
POWER TRAIN - AUTOMATIC TRANSMISSION - PARK/NEUTRAL START SWITCH
0118109/17/2001625715Brake shift interlock.*jb11/30/2001
POWER TRAIN - AUTOMATIC TRANSMISSION - TORQUE CONVERTER
9624911/18/199650908Torque converter - leak test procedure - service tip. *tw06/17/1997
96261212/16/199650997Transaxle - torque converter replacement guidelines and torque converter/transaxle cooling system cleaning procedures - service tip. *tw06/17/1997
POWER TRAIN - AXLE ASSEMBLY
9823311/23/1998603717Concerns with front drive axle fluid may leak out of the vent under some driving modes on some vehicles. *yc03/03/1999
BC243197050105/01/199752834Aerostar e4wd models may experience front axle lubricant leakage from the vent tube under some driving conditions. *tw09/18/1997
POWER TRAIN - MANUAL TRANSMISSION
BC067896102510/25/199650356Information on aode/4r7w transmission main control & case replacement. *tt04/24/1997

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
POWER TRAIN
EA99002FORD MOTOR COMPANY01/07/199911/14/2000TRANSFER CASES AND REAR DRIVE SHAFT99V094000
 Powertrain bending resonance and/or transfer case rear drive shaft bushing displacement can cause structural failure of the transmission
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
RQ98012FORD MOTOR COMPANY07/31/199801/07/1999TRANSFER CASES AND REAR DRIVESHAFT97V204000
 Powertrain bending resonance or transfer case output shaft busihing displacement, resulting in structural failure of the transmission and/or transfer case driveshaft separation, loss of fluid and fire potential

Consumer Complaints

Fail datemilesoccurencesPurchase date
POWER TRAIN
1
 The speedometer cluster quit working past 100,000 miles, there was no way to tell the vehicles speed. nlm
10/16/1995509/01/1994
 Exhuast fumes are leaking into the passenger compartment and cause the passengers to become sick. tt the odometer malfunctions. oil lights and engine light continue to come on because the vehicle burns 1-2 quarts of oil every week. brakes stick and there was bricks rubbing kind of sound when the steering wheel turns. the horn failed. the weather stripping around the slide door keep coming off. *yh
POWER TRAIN - AUTOMATIC TRANSMISSION
05/25/20031
 Consumer states that the gear shift can be pushed down without applying the brake. dealer notified.*ak
12/04/2002105/08/1999
 Automatic transmission failure - transmission falls out of gear. *jb
06/21/2001209/01/1996
 While driving in the smoky mountains in nc the transmission overheated and poured out transmission fluid. the van began to smoke and i pulled over in a dangerous place. i decided to turn around (also in dangerous place) i went back to cherokee, nc and a mechanic said this was a common problem for areostars. he said many people get ripped off by untrustworthy mechanics. while traveling over the mountains we saw three other areostars with the same problem. two were being towed by wreckers. areostar owners need to be notified of this problem. that the transmission will overheat under a load and transmission fluid will be lost. we were very upset by this and our vacation was ruined. but because we found a good mechanic we were not ripped off. i cannot say the same about the other vans that we saw being towed from the mountain and we were only there for a couple of hours and saw three others in trouble.*ak
03/27/2000101/08/2000
 Transmission failed, vehicle was stuck in drive, shavings were found in the transmission pan, dealer also replaced the shifter cable. *slc
02/03/2000207/01/1999
 Transfer case problems began when fluid was leaking. took to mechanic, who replaced the gaskets. about a month later the transmission went out, and was rebuilt by different mechanic. fluid continued to leak, gaskets were replaced a second time. fluid spewed during driving, which mechanic said was due to catalytic converter blowing hot air on transmission fluid, causing its release. replaced catalytic converter. fluid still continued to spew, all over the underside of the vehicle. it was driven 120 miles, a qt. of transmission fluid added, and back 120 miles, with another qt. added. mechanic takes transfer case apart, finding the bearings worn to a non-round shape, and the shaft end worn down. checked for recall, and there is one, 99v094000 but ford says our van doesn't fall into this recall and refuses to help.
 Vehicle would not travel over 35 mph. transmission has been rebuilt two times.however, problem returned after repairs. please provide further information. *ak
09/11/19990
 While driving vehicle hesitated for about 40 seconds. dealer flushed out fluid and it got worse. consumer said it was the exact recall listed on web. *ak
03/01/19991
 Recall work completed on the transfer case on july 1998, however transmission needed to be rebuilt on march 1999, transfer case was leaking. mjs
08/01/1994307/01/1994
 No summary.
10/04/1997111/01/1995
 November 21, 1998 this complaint has already been investigated and a recall has been ordered. we had already repaired our 1994 ford aerostar van because it broke down on october 4, 1997. we submitted a request for reimbursement on august 7, 1998. as of november 21, 1998, we have not received a reimbursement check. is there a window of time for the manufacturer to mail reimbursement checks? i feel that ford motor company should reimburse me for expenses incurred as a result of the defect plus interest and late fees for failing to send a reimbursement check within a reasonable time (3 weeks). i feel that $3,292.60 would be a fair reimbursement at this time. ford motor co. has been collecting interest on the money it owes its customers or investing it. safety recall number: 97s83 campaign # 97v204000 i submitted receipts to: stanley carroll radford ford, inc. 6832 lee highway radford, va 24141 (540) 639-3934 i have contacted the ford customer assistance center 1-800-392-3673 several times as well as mr. carroll. they promise to check into the progress of my reimbursement and call back. they do not call back. thank you in advance for your time and careful consideration of my message. sincerely, carolyn c. mccain (540) 731-1945 (h) (540) 674-4663 (w) ccmccain@aol.com
1
 Transmission/transfer case failed.
12/28/1997110/21/1994
 Transmission failed.
07/24/1997204/02/1995
 Recall no. 97v204000; changing the transfer case is not correcting the problem because the transfer case has been replaced twice before the recall was issued. long distance driving heats the transfer case and causes leakage. *ak when inspecting transfer case, it appeared to have been installed incorrectly, it was leaking and there were loose bolts and hairline cracks in the transmission, consumer is requesting reimbursement. *slc
 Vehicle's transmission completely went out with no warnings or signs. dealer won't replace. *ak
07/26/199709/12/1994
 Vehicle does not go into parkdue to the the transmission cable melting because it was mounted to close to the rod. *ak
POWER TRAIN - AUTOMATIC TRANSMISSION - COOLING UNIT AND LINES
08/01/1997502/01/1995
 This van releases automatic trans. fluid from the seal between the torque converter and the transmission body. it does this when hot (but not overheating), in the summer, while towing a light weight camping trailer (load within ford towing limits). this occurs typically while climbing, but also on a flat grade at high speeds (65-70 mph) in hot temperatures (85f +). the fluid squirts onto the exhaust pipe, releasing large amounts of smoke. there was a previous recall on this van for a similar problem with releasing trans. fluid onto the exhaust pipe, and i had the recall work done, but it involved the transfer case and driveshaft, not the torque converter to transmission seal. i have had a large aftermarket trans. cooler installed as well as a trans. fluid temp. guage. the engine coolant and trans. fluid are within normal temp. limits when these incidents occur. the dealer service dept. has told me that this problem would not be fixed by replacing the seal; that it would continue because of component limitations. although the drivetrain components have not been detectably mechanically damaged by these incidents, the incidents are a clear safety hazard because of the fire hazard as well as the possible loss of control if the drivtrain components were to fail precipitously. when these incidents occur, i have to pull over immediately and shut off the engine and let the trans. cool for a time, and this is another safety hazard because there is not always a safe place to pull over. i believe that the previous recall for this (or a similar) problem did not result in an adequate fix and that the issue should be re-examined. the date of the incident noted on this report was the first occurrence.
POWER TRAIN - AUTOMATIC TRANSMISSION - GEAR POSITION INDICATION (PRNDL)
03/17/1998207/30/1995
 Gear shift cable broke twice. *ak
POWER TRAIN - AUTOMATIC TRANSMISSION - LEVER AND LINKAGE - COLUMN SHIFT
05/09/2002304/02/1995
 The tranfer case heated up and separated from the transmission in the process the transmssion was cracked and replaced, three times by the manufacturer.*jb the transfer case was recalled (97v-204) by the manufacturer after the transmission had failed three times. *yh
03/27/2000101/08/2000
 Transmission failed, vehicle was stuck in drive, shavings were found in the transmission pan, dealer also replaced the shifter cable. *slc
08/14/1998305/01/1996
 Recall required that the transfer case be repaired, it was replaced with a defective one. the electronic clutch in the new transfer case started making popping sounds at approx. 8057 miles. problem reported while under recall part warrantee but i was told the transfer case would not make that sound. it did and later failed catastrophically. it was dangerous to drive vehicle under those circumstances, ford should replace defective unit with a good one but refuse to do so. *ak
207/01/1995
 This aerostar van has been an extremely good vehicle until we recently started having problems with the front transfer case. we received a recall in 1998 for the transfer case, although all that was replaced was the rear case. about 1 year later we started having leakage from the front transfer case. we returned the truck to the dealer and they stated that this was not part of the recall, but we would have to have this crack repaired. we went to several transmission repair facilities and they indicated that they see this crack in the front case frequently in the aerostar van. we have had it welded, but will not take the van out on the highway. we want it replaced and if it is happening as frequently as they say, it is certainly a safety issue. *ak
07/24/1996807/01/1994
 Transfer case has repeatedly leaked and eventually blew. it has been worked on/replaced 8 times. still leaking after recall replacement (97v204000). dealer refuses to replace under warranty due to their 12 months/12000mi parts policy. *ak
08/10/19971
 Transfer case failed prior to recall notice, however repair is not sufficient or proper, original transfer case replaced without the aluminum driveshaft installation.
1
 Transmission/transfer case failed.
03/15/19958
 Was driving 7 kids in vehicle, going about 45mph, when transfer case was leaking under normal driving conditions. another truck forced aerostar off road due to being on fire. flames had made tank glow red. flames put out w/fire extinguisher. vehicle towed to ford dealer. repairs done on transfer case under recall 97v-204.000. took vehicle home & parked it. started to leak. this was the 8th transfer case replaced in vehicle & the 2nd to catch on fire.manufacturer agreed to buy vehicle back from owner at price it was paid for. *ak
08/01/1997103/01/1996
 Transfer case failed causing loss of fluid.
01/01/1996407/24/1994
 Transfer case failed four times. *ak
07/24/1997204/02/1995
 Recall no. 97v204000; changing the transfer case is not correcting the problem because the transfer case has been replaced twice before the recall was issued. long distance driving heats the transfer case and causes leakage. *ak when inspecting transfer case, it appeared to have been installed incorrectly, it was leaking and there were loose bolts and hairline cracks in the transmission, consumer is requesting reimbursement. *slc
09/14/1996110/25/1995
 Transfer house failed.
105/19/1995
 Transfer case busted.
08/06/19961
 Rear transfer case oil boils/blows out of vent onto transfer case which is located near gas tank.
POWER TRAIN - AUTOMATIC TRANSMISSION - PARK/NEUTRAL START SWITCH
11/25/2001103/01/1995
 After consumer parked vehicle and took key out of ignition, while getting out of vehicle, it started rolling backward, consumer was caught by door, bruised badly. vehicle was stopped by a tree. since it rolled very slowly there was no damage. vehicle not taken to dealer yet. *ak *slc
POWER TRAIN - AXLE ASSEMBLY
11/30/2001
 Rear passenger side wheel came off while consumer was driving up a slight incline. dealer has been contacted, and informed consumer that axles were deffective. please provide further details. *ak
POWER TRAIN - AXLE ASSEMBLY - AXLE SHAFT
05/29/1996201/20/1994
 Rear drive train failure.
POWER TRAIN - CLUTCH ASSEMBLY - BELL HOUSING
06/20/2006120000403/22/2005
 Front coil springs snapped, had to replaced with reading spring works, they had to send the specks to chicago. my ford aero star 4 wheel drive & 4.0 v6 is not available from after market. the only option is to buy new or used ford springs which are made in china. the local ford dealer admits replacing coil & leaf springs on several models. midas was so busy replacing ford springs, they could not set up an appointment to install springs even if i had the springs. *tr
06/03/1996105/19/1995
 Extension housing were busted.
POWER TRAIN - CLUTCH ASSEMBLY - PEDAL/LINKAGE
05/05/19981
 Was driving vehicle about 40mph. noticed vehicle started going in neutral. took to dealer & nothing was done by mechanics. decided to take vehicle to amoco. mechanic found 2 clutches fused together. friction plates between clutch disintergrated. bushings burnt out & warped pump. *ak
POWER TRAIN - DRIVELINE - DIFFERENTIAL UNIT
02/03/2000207/01/1999
 Transfer case problems began when fluid was leaking. took to mechanic, who replaced the gaskets. about a month later the transmission went out, and was rebuilt by different mechanic. fluid continued to leak, gaskets were replaced a second time. fluid spewed during driving, which mechanic said was due to catalytic converter blowing hot air on transmission fluid, causing its release. replaced catalytic converter. fluid still continued to spew, all over the underside of the vehicle. it was driven 120 miles, a qt. of transmission fluid added, and back 120 miles, with another qt. added. mechanic takes transfer case apart, finding the bearings worn to a non-round shape, and the shaft end worn down. checked for recall, and there is one, 99v094000 but ford says our van doesn't fall into this recall and refuses to help.
11/10/19941
 Limited slip differential fails to control vehicle when driving in snow or ice. *skd
POWER TRAIN - DRIVELINE - DRIVESHAFT
05/28/1999111/01/1997
 My clients, the frederick family (father, mother and 3-yr-old daughter) sustained third degree burns when their 1994 ford aerostar van spontaneously caught fire while travelling on i-40 near needles, california. fire was the result of the transfer case output shaft bushing displacement, thereby failing the drive shaft which struck the pavement, then richocheted into the fuel tank and pierced the tank, allowing raw fuel to escape and ignite, probably from the catalytic converter or sparks from the drive shaft striking the pavement. this case is in litigation in united states district court in las vegas, nevada, being case no. cv-s-00-0444-ktd-rlh. peter chase neumann, attorney for plaintiffs, 136 ridge street, reno, nv 89501. 775-786-3750.
08/10/19971
 Transfer case failed prior to recall notice, however repair is not sufficient or proper, original transfer case replaced without the aluminum driveshaft installation.
POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE)
212/11/1995
 Transfer case failed prior to recall notice (97v-204)leaving consumer and family stranded. driveshaft should have been changed to an aluminum one at time of recall repair of the transfer case to fully remedy the transmission problem. consumer is hearing transmisson noises again. nlm
08/13/1998305/01/1995
 In march of 1995 i took custody of my three nieces, due to their mother's addiction to meth. at that point we owned a ford excort, which we traded in on the ford aerostar in may of that year, with approximately 18,000 miles. when the van reached approx. 55,000 miles my wife was driving in phoenix and the transfer case went out, while she was driving around 35 mph. since the component was under warranty pioneer ford replaced the component, and this only took them 5 to 6 weeks. in august of 1998 the transfer case went out again, with approx. 108,000 miles, and this time the ford dealer in blythe replaced the component and drive shaft under a recall notice. less than 12 months later, on august 13, 1999, the transfer case went out again. we took it to firestone and they thought the problem was a cv joint, which they replaced. the problem continued and they sent us to bob turner's ford in albuquerque, nm. even though firestone had informed them of the problem, they proceeded to say it was bad cv joints (including the new one) and replaced these and other misc. at a cost of $900.00 and the problem still exist. they now inform me that it is the transfer case and it will cost $2500.00 to fix. i contacted ford about this problem and the fact that 3 transfer cases in 3 years is not acceptable, but they refuse to help in this matter. when i talked to a person at customer service, he said ford would replace the part if defective, i then asked paul at bob turner's ford if the part was defective, and he said yes but ford now says that since it has over 12,000 miles they will do nothing. i do not believe that a vehicle that has never been in 4-wheel drive should have gone through 3 transfer cases in 3 years, this is a defect to me and the many mechanics that i have talked to. please look into this matter and let me know what can be done, for i can not be the only person in this situation.
07/01/19973
 01-jul-97 transfer case failed prior to recall notice (97v204000) during 1st repair dealership replaced transmission fluid w/ engine oil resulting in complete transmission repair. recall replacement on 7-01-98 ( attorney for consumer ). *yc
12/23/1996112/11/1995
 Transfer case broke while driving prior to recall notice.
09/01/1996107/11/1994
 Transfer case failed in two year old vehicle. learned after replacement, that there is a recall on transfer case; should there be a reimbursement?
08/25/1996
 Failure of the transfer case, consumer was driving and the transfer case broke, causing the consumer to have a near accident.*ak

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