Ford Aerostar Recalls — All NHTSA Recall Campaigns

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

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 INSTA…

Risk: A LEAKING FUEL PUMP COULD CREATE A VEHICLE FIRE HAZARD.

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.

ELECTRICAL SYSTEM:IGNITION:SWITCH

VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES WERE PRODUCED WITH A HIGHER THAN SPECIFIED ELECTRICAL LOAD THROUGH THE ACCESSORY POWER FEED CIRCUIT. THE POTENTIAL FOR CONTACT BETWEEN THE B2 (BATTERY), A2 (ACCESSORY), AND P1 (PROOF) CIRCUITS CAN OCCUR, CREATING A SHORT CIRCUIT, ALLOWING CURRENT TO …

Risk: THIS CAN CAUSE OVER HEATING AND THE POTENTIAL FOR A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL A JUMPER HARNESS WITH A RELAY WHICH WILL RE-ROUTE AND ACTIVATE ALL A2 ACCESSORIES THROUGH THE RELAY.

SERVICE BRAKES, AIR:DISC:ROTOR

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.

Risk: LOSS OF BRAKING CAN RESULT.

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 F…

SEAT BELTS:FRONT:ANCHORAGE

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.

Risk: DAMAGE TO BELT WEBBING COULD WEAKEN BELTS TO POINT OFFAILURE INCREASING RISK OF INJURY IN AN ACCIDENT OR A SUDDEN STOP.

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

ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD

VEHICLE DESCRIPTION: MINI VANS. HEAT GENERATION IN THE WIRING HARNESS TO THE FUEL PUMP/SENDER ASSEMBLY CAN CAUSE AN ELECTRICAL SHORT. THE VEHICLE COULD EXPERIENCE A LOSS OF POWER AND BECOME IMMOBILIZED AND THE FUEL GAUGE MAY BE ERRATIC.

Risk: HEAT DAMAGE, INCLUDING MELTING OR CHARRING OF THE FUEL PUMP AND SENDER ASSEMBLY WIRE HARNESS AND ASSOCIATED WIRING HARNESSES CAN ALSO RESULT. THE SHORT CIRCUIT COULD ALSO HAVE THE POTENTIAL FOR A VEH…

Remedy: DEALERS WILL INSTALL A FUSED JUMPER HARNESS IN THE FUEL PUMP GROUND CIRCUIT THAT WILL BE INSTALLED AT THE FUEL PUMP INERTIA SHUT-OFF SWITCH.

EQUIPMENT:MECHANICAL:CARRIER/RACK

THE SPARE TIRE SUPPLIED WITH THE VEHICLE CAN CONTACT THE BRAKE LINES ON THE REAR AXLE IF IT IS MOUNTED IN THE UNDERBODY SPARE TIRE CARRIER. SUCH CONTACT COULD RESULT IN FRACTURE OF A REAR BRAKE LINE.

Risk: THIS CAN RESULT IN REDUCED VEHICLE BRAKE CAPABILITY.

Remedy: DEALERS WILL INSTALL A LOWER PROFILE MINI-SPARE TIRE ON THE EXISTING MINI-SPARE WHEEL. THE NEW TIRE WILL ALLOW THE MINI-SPARE TO BE INSTALLED WITH APPROPRIATE CLEARANCES IN THE UNDERBODY SPARE TIRE C…

POWER TRAIN:AUTOMATIC TRANSMISSION

WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.

Risk: DRIVER MAY BELIEVE THE VEHICLE IS SAFELY ENGAGED IN PARKWHEN THE GEAR IS NOT TRULY ENGAGED. THIS CAN LEAD TO THE VEHICLE JUMPING OUT OFGEAR UNINTENTIONALLY, VEHICLE ROLLAWAY WHEN PARKED ON A SLOPED SU…

Remedy: REPAIR THE TRANSMISSION WITH A NEW PARK PAWL.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

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.

Risk: IN THE PRESENCE OF AN IGNITION SOURCE, FUEL LEAKAGE COULD RESULT IN A FIRE.

Remedy: INSTALL A REVISED DESIGN GROMMET.

ELECTRICAL SYSTEM:WIRING

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.

Risk: SHOULD A SHORT CIRCUIT OCCUR IN THE WIRING WITHIN THERELAY OR IF WATER INTRUSION OCCURS THE SMALLER GAUGE WIRE IN THE RELAY WILLFUNCTION AS A FUSE LINK AND OVERHEAT. THE POSSIBILITY EXISTS FOR A FIRE…

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

SEATS

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

Risk: THIS COULD RESULT IN A SHORT CIRCUIT WHICH MAY CREATESUFFICIENT HEAT TO START A FIRE IN THE SEAT CUSHION PAD AND/OR TRIM COVER.

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

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Risk: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

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

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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 …

Remedy: REPLACE FUEL TANKS AS NECESSARY.

SUSPENSION:REAR:SPRINGS:LEAF SPRING ASSEMBLY

THERE MAY BE INADEQUATE WELDING IN SOME UNDERBODY STRUCTURAL AREAS, INCLUDING THOSE AT THE REAR SUSPENSION ATTACHMENTS, WHICH MAY CAUSE IT TO SEPARATE. …

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

SEAT BELTS:FRONT:ANCHORAGE

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.

Risk: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.

Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

ELECTRICAL SYSTEM:IGNITION

THE IGNITION SWITCH COULD EXPERIENCE AN INTERNAL SHORT CIRCUIT.

Risk: THIS CONDITION COULD CAUSE OVERHEATING, SMOKE, AND POSSIBLY FIRE IN THE STEERING COLUMN AREA OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE IGNITION SWITCH.

SERVICE BRAKES, HYDRAULIC

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 …

Risk: 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.

Remedy: 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 1-800-32…

POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

VEHICLE 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/O…

Risk: THIS CONDITION CAN CAUSE A LOSS OF VEHICLE CONTROL, AND, IF THE EXPELLED FLUID CONTACTS THE EXHAUST SYSTEM, A VEHICLE FIRE COULD OCCUR.

Remedy: DEALERS WILL INSTALL A NEW TRANSFER CASE REAR OUTPUT SHAFT BUSHING AND AN ALUMINUM DRIVESHAFT WILL BE INSTALLED.

EQUIPMENT:OTHER:LABELS

THE CERTIFICATION LABEL ON THESE VEHICLES HAVE INCORRECT REAR TIRE SIZES LISTED. P215/70R14SL SHOULD BE P215/75R14SL. THIS DOES NOT COMPLY WITH FMVSS NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."

Risk: CONSEQUENCE OF NON-COMPLIANCE: THE INCORRECTLY SIZED REAR TIRE WOULD NOT HAVE SUFFICIENT LOAD CAPACITY FOR THE VEHICLE'S SPECIFIED GROSS AXLE WEIGHT RATING, INCREASING THE POTENTIAL FOR PREMATURE TIR…

Remedy: OWNERS WILL BE MAILED A SUPPLEMENTARY LABEL CONTAINING THE CORRECT REAR TIRE INFORMATION AND INSTRUCTIONS FOR INSTALLING THE LABEL ON THEIR VEHICLES. IF OWNERS PREFER, THEIR DEALER CAN INSTALL THE LA…

VEHICLE SPEED CONTROL:CABLES

VEHICLE DESCRIPTION: MINIVANS EQUIPPED WITH 3.0L ENGINES. AN ACCELERATOR CABLE WAS KINKED DURING INSTALLATION, CAUSING THE CORE WIRES TO EVENTUALLY FRAY.

Risk: THIS COULD INCREASE THE FRICTION IN THE CABLE, CAUSING THE THROTTLE TO BE SLOW TO RETURN TO IDLE. THIS CONDITION COULD RESULT IN A STUCK THROTTLE.

Remedy: DEALERS WILL INSTALL A NEW ACCELERATOR CABLE.