FordAerostar1991Overview/ford/aerostar/1991/base/

1991 Ford Aerostar

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1991 Aerostar.

The 1991 Ford Aerostar is a vehicle that uses a 4.5‑qt engine oil system specified at 5W‑30 API viscosity. It recorded 260 total owner complaints, with the Electrical System as the primary complaint area and four recall campaigns issued. Within the model’s 1990‑2000 complaint history, the 1991 year falls toward the lower end of the spectrum, reflecting a relatively healthier reliability record compared with the peak 1993 complaints of 471 and the 1998 low of four complaints.

Model year199719961995199419931992199119901989

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified
Engine oil type5W-30 APIOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

OE service part numbers OEM · verified

ThermostatRT1054

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length174.8 in
Overall width71.7 in
Overall height72.8 in
Wheelbase118.9 in
Curb weight3206 lb

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil, GL-5 in the differential, DOT 3 brake fluid.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear OilGL-5
Differential Gear Oil Capacity2.5 pints Dana Axle
Differential Gear OilGL-5
Differential Gear Oil Capacity5 Pints Ford 8.8
Differential Gear OilGL-5
Differential Gear Oil Capacity3.5 pints Rear Ford 7.5
Engine Oil5W-30 · API

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 30,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 miTire & Wheel Assembly (rotate)
Every 7,500 miClutch Master Cylinder (inspect fluid level) · Driveshaft U-Joint (lubricate) · Engine Oil (drain & refill) · Engine Oil Filter (replace) · Power Steering System (inspect) · Shift Linkage (lubricate)
Every 15,000 miBrake System (inspect) · Disc Brake Caliper Guide Pin (lubricate) · Parking Brake System (inspect) · Tire & Wheel Assembly (rotate)
Every 30,000 miBrake Hydraulic System (inspect fluid level) · Engine Air Filter Element (replace) · Engine Breather Filter (replace) · Engine Coolant System (drain, flush & refill) · Spark Plugs (replace) · Throttle Body Lever Stud (lubricate)
Every 60,000 miAccessory Drive Belt (inspect) · Exhaust System (Complete) (inspect) · Idle Air Bypass Solenoid (inspect) · PCV Valve (replace) · Spark Plug Wires (replace) · Throttle Body (inspect)
Every 100,000 miDrive Axle Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 1991 model year represents an early production phase for the Aerostar, posting 260 complaints—modestly higher than 1990's 238 but significantly below the 367 to 471 annual volumes that characterize the 1992-1993 peak. Federal oversight intensity was notably lower this year, with recalls dropping to 4 from 1990's 7 and investigations falling to 2 from 5, suggesting reduced regulatory scrutiny compared to both the prior year and the subsequent 1992-1994 period when investigations consistently held at 5. Technical service bulletins remained minimal at 48, preceding the steep escalation to 62-90 range in following years. While 1991 carries 75 fire-related and 26 crash-related complaints alongside electrical system reports, it sits at the beginning of an upward reliability curve that crests in 1993. Given its position before the worst complaint years and its lower recall burden relative to 1990, 1991 represents a relatively favorable vintage within this generation for a used vehicle purchase, provided thorough pre-purchase inspection addresses the documented electrical and powertrain complaint concentrations.

4
Open recalls
NHTSA campaigns
48
Service bulletins
Manufacturer communications
2
ODI investigations
Office of Defects Investigation
260
Owner complaints
26 involved a crash · 75 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 260 complaints on record, top 8 components.

Electrical System72
Power Train47
Service Brakes, Hydraulic29
Vehicle Speed Control22
Equipment14
Engine & Engine Cooling12
Structure10
Latches/Locks/Linkages7

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

98E010000Service Brakes, Air:Disc:RotorReported 08/04/1998

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…

91V164000Seat Belts:Front:AnchorageReported 20/09/1991

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210. Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Technical service bulletins NHTSA · verified

Showing 5 of 48 bulletins on record with NHTSA.

BulletinDateComponentSummary
021422002-07-22Engine And Engine CoolingSOME VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION AND A 4.0L OHV ENGINE MAY EXHIBIT A…
011972001-10-01Engine And Engine CoolingSOME VEHICLES EQUIPPED WITH THE 4.0L OHV ENGINE MAY EXHIBIT AN ENGINE NOISE WHICH MAY BE…
011562001-08-06VisibilitySOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS. *SLC
011572001-08-06Unknown Or OtherINFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS. *SLC
011242001-06-25Engine And Engine CoolingON SOME VEHICLES, ENGINE OIL MAY CONTINUE TO LEAK FROM THE ENGINE OIL PAN GASKET AREA…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Aerostar. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 1991 Aerostar take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 1991 Aerostar have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.