1986 Ford Aerostar — Problems, Recalls & Complaints

CERTAIN FEDERAL-MOGUL AFTERMARKET FUEL PUMPS SOLD UNDER THE BRAND NAMES OF CARTER, ACCUFLOW, NAPA, TRUFLOW, PARTS DEPO, AND PARTS MASTER, SHIPPED BETWEEN AUGUST 2006 AND JULY 2007 FOR USE ON THE VEHICLES LISTED ABOVE. THE FUEL PUMP DIAPHRAGM IN CERTAIN PRODUCTION RUNS MAY HAVE BEEN IMPROPERLY INSTALLED OR INADEQUATELY TESTED WHICH MAY CAUSE THE FUEL PUMP TO LEAK.

Remedy: FEDERAL-MOGUL WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 15, 2007. OWNERS CAN CONTACT FEDERAL-MOGUL AT 248-354-7700.

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.

Remedy: 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.

VANS WERE PRODUCED WITHOUT PLASTIC COVER DESIGNED TO COVER OUTBOARD SEAT BACK PIVOT HINGE ALLOWING WEBBING OF FRONT PASSENGER-SIDE SAFETY BELTS TO BECOME ABRADED OR CUT DUE TO CONTACT WITH EXPOSED HINGE.

Remedy: INSTALL PLASTIC PIVOT COVER; REPLACE BELTS AS NECESSARY.

INSUFFICIENT INTERFERENCE FIT BETWEEN FUEL TANK FILLER PIPE AND GROMMET COULD RESULT IN AN INADEQUATE SEAL WHICH COULD ALLOW FUEL TO SEEP FROM THE JOINT.

Remedy: INSTALL A REVISED DESIGN GROMMET.

WIRING FOR THE POWER LUMBAR SEAT SYSTEM WAS ROUTED DIRECTLY BENEATH THE SEAT CUSHION SPRINGS AND MAY BE ABRADED BY THE SPRINGS.

Remedy: INSTALL A FUSE WITHIN THE POWER LUMBAR ELECTRICAL CIRCUIT.

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Remedy: INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE.

FUEL TANKS MAY HAVE BEEN SCORED OR PENETRATED WHEN FLOOR PAN MOUNTING HOLES FOR THE PARTITIONS WERE DRILLED. CONSEQUENCE OF DEFECT: FUEL LEAKAGE MAY OCCUR AND IN THE PRESENCE OF AN IGNITION SOURCE, THE POTENTIAL FOR A FIRE WOULD EXIST.

Remedy: REPLACE FUEL TANKS AS NECESSARY.

VEHICLES EQUIPPED WITH TRAILER TOW PACKAGE HAVE A TRAILER TAILLIGHT RELAY ASSEMBLY THAT CONTAINS WIRES OF SMALLER GAUGE THAN THE FUSE LINK WHICH PROTECTS THE CIRCUIT.

Remedy: INSTALLATION OF A RELAY WITH WIRES OF GAUGE ADEQUATE TO PROTECT THE CIRCUIT.

THERE MAY BE INADEQUATE WELDING IN SOME UNDERBODY STRUCTURAL AREAS, INCLUDING THOSE AT THE REAR SUSPENSION ATTACHMENTS, WHICH MAY CAUSE IT TO SEPARATE. CONSEQUENCE OF DEFECT: IF REAR SUSPENSION ATTACHMENTS SHOULD SEPARATE FROM THE UNDERBODY DURING VEHICLE USE, THE AXLE COULD SHIFT DURING ACCELERATION OR BRAKING AND MAY ADVERSELY AFFECT THE STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT.

Remedy: REINFORCE SUSPECT WELD LOCATIONS AND MODIFY TO PREVENT WELD FAILURE.