One problem related to brake disc has been reported for the 1996 Ford Aerostar. The most recently reported issues are listed below.
As promised, I'm back. Major brake failures at 32,518, 55,638, and recently at 58, 700. I checked your site through the cartalk website and found 12 brake problems reported out of 79. I am not the only owner whose family is at risk. Mosy recently, the brake pedal bottomed out two consecutive times at slow speed. The passengers in the car said they smelled heated brakes. I believe the calipers may be dragging, overheating the brakes. I cannot duplicate the problem. We owned an Aerostar previously and had no such brake problems, certainly not a pad replacement at 32,000. These brakes are wearing prematurely. Although the car was under warranty, we were charged for pad replacement and rotor resurfacing. Ms brenner, the principal driver noticed a grinding sound which cased her to take it in for service. I believe the dealer was wrong to charge us for this repair, as brakes do not wear this quickly. I believe that the pad of caliper failed, unrelated to the wear. Our honest, competent independent mechanics, b&m automotive inmc lean, va (703)356-1532 tell us that they see many problems with Ford brakes. What's it going to take, folks? does somkeone have to lose his life at the hands of Ford before you recall these cars?.