1991 Ford Aerostar

Introduction

The 1991 Ford Aerostar was a popular minivan offered with a variety of engine and transmission options. It was known for its spacious interior, versatile seating configurations, and powerful V6 engines. However, like any vehicle, the Aerostar had its share of common issues.

Engine

3.0L V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leaks, overheating, rough idle
  • Solution: Replace intake manifold gasket
  • Estimated Cost to Fix: $300 - $500
• Timing Chain Tensioner Failure
  • Description/Symptoms: Rattling noise on startup, loss of power
  • Solution: Replace timing chain tensioner
  • Estimated Cost to Fix: $400 - $600

4.0L V6

• Cylinder Head Gasket Failure
  • Description/Symptoms: Coolant leaks, overheating, white smoke from exhaust
  • Solution: Replace cylinder head gasket
  • Estimated Cost to Fix: $1000 - $1500+
• Piston Ring Failure
  • Description/Symptoms: Excessive oil consumption, blue smoke from exhaust
  • Solution: Replace piston rings
  • Estimated Cost to Fix: $1500 - $2000+

Transmission

A4LD

• Shift Solenoid Failure
  • Description/Symptoms: Transmission slipping, hard shifting
  • Solution: Replace shift solenoid
  • Estimated Cost to Fix: $200 - $400
• Overdrive Servo Failure
  • Description/Symptoms: Transmission stuck in overdrive, no overdrive
  • Solution: Replace overdrive servo
  • Estimated Cost to Fix: $300 - $500

E4OD

• Torque Converter Failure
  • Description/Symptoms: Transmission shudder, slipping, no movement
  • Solution: Replace torque converter
  • Estimated Cost to Fix: $800 - $1200+
• Planetary Gear Failure
  • Description/Symptoms: Grinding noise, loss of power
  • Solution: Replace planetary gear set
  • Estimated Cost to Fix: $1500 - $2000+

Suspension

• Front Ball Joint Failure
  • Description/Symptoms: Clunking noise, steering instability
  • Solution: Replace ball joint
  • Estimated Cost to Fix: $200 - $400+
• Rear Leaf Spring Breakage
  • Description/Symptoms: Sagging rear end, rough ride
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $500 - $800+

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, battery drain
  • Solution: Replace alternator
  • Estimated Cost to Fix: $300 - $500+
• Battery Terminal Corrosion
  • Description/Symptoms: Difficulty starting, electrical system malfunctions
  • Solution: Clean or replace battery terminals
  • Estimated Cost to Fix: $50 - $100+

Exterior

• Rust Prone
  • Description/Symptoms: Rust spots on body panels, frame
  • Solution: Rust repair or replacement
  • Estimated Cost to Fix: Varies greatly depending on extent of damage

Interior

• Door Panel Sagging
  • Description/Symptoms: Loose door panels, rattling
  • Solution: Reattach door panel clips
  • Estimated Cost to Fix: $0 - $50+
• Heater Core Failure
  • Description/Symptoms: No heat, coolant leaks
  • Solution: Replace heater core
  • Estimated Cost to Fix: $400 - $600+

Summary

Overall, the 1991 Ford Aerostar is a reliable vehicle with a spacious interior and powerful engines. However, like any used car, it can have its share of issues. The most common problems include engine gasket failures, transmission solenoid issues, suspension wear, and electrical problems. The severity and cost of these issues can vary widely, so it’s important to have the vehicle inspected by a qualified mechanic before purchasing.