Ford Aerostar Cargo: Price, Mileage, Features, Specs, Variants, Engine, Interior, History & More

Brief Introduction of Ford Aerostar Cargo

The Ford Aerostar Cargo is a variant of the Ford Aerostar, a minivan manufactured by Ford from the 1986 to 1997 model years. As Ford’s first minivan, the Aerostar was developed to compete with the Chevrolet Astro/GMC Safari and the Chrysler minivans. The Cargo version was specifically designed for commercial use, featuring a spacious interior and often distinguished by double rear doors and a lack of side windows. Its design was notably aerodynamic for its time, with a sloped “one-box” exterior that contributed to a drag coefficient of 0.37, which was better than some contemporary passenger cars. The Aerostar was built on a unique platform combining unibody construction with full-length frame rails, giving it a robust towing capacity. It was produced in a single generation with several updates and was available in both standard and extended-length body styles.

Ford Aerostar Cargo Overview

Generations and History of Ford Aerostar Cargo

The Ford Aerostar was produced over a single, yet evolving, generation from its introduction in 1985 for the 1986 model year until its discontinuation after the 1997 model year. It was Ford’s inaugural entry into the minivan market and was marketed as a light truck. The Aerostar Cargo van was a key part of the lineup from the beginning, designed as a versatile work vehicle. It was assembled exclusively at Ford’s St. Louis Assembly Plant in Hazelwood, Missouri. Despite the introduction of its front-wheel-drive successor, the Ford Windstar, in 1995, the Aerostar continued to be sold concurrently for three years due to popular demand from both the public and dealerships. In total, over two million Aerostars were produced during its run.

First Generation (1986-1997)

The Aerostar made its debut with a distinctive, aerodynamic design that set it apart from its competitors. Initially, the powertrain choices included a 2.3L four-cylinder engine and an optional 2.8L V6. Midway through its first year, the 2.8L was replaced by a more powerful 3.0L Vulcan V6. The cargo version offered practical features like double rear doors and could be configured without side windows to maximize utility and security for transported goods. The van’s construction was a hybrid of unibody and frame-on-body design, which gave it a significant towing capacity of up to 5,000 pounds, far exceeding its front-wheel-drive rivals. The interior was designed to be spacious, capable of accommodating a 4×8 sheet of plywood. The Aerostar was a rear-wheel-drive vehicle, with an all-wheel-drive option introduced later in its production run.

Ford Aerostar Cargo Facelifts and Yearly Updates

Ford Aerostar Cargo Variants and Features

The Ford Aerostar Cargo was available in several configurations to suit different commercial needs. It came in both a standard-length and an extended-length body style, with the latter offering significantly more cargo volume. Variants included a basic cargo van with no side windows for maximum security and a “Window Van” version that provided more visibility. Trim levels were generally simpler than the passenger versions, often falling under the “base” or XL designation. Inside, the cargo van was spartan, focusing on utility with seating typically for two occupants. The removal of passenger seats created a cavernous cargo area, with the extended version boasting up to 170 cubic feet of space. Standard features were minimal in the early models, though some conveniences like air conditioning could be optioned. Later models saw the addition of safety features like a driver-side airbag.

Ford Aerostar Cargo Engine, Performance, and Driving Experience

The Aerostar’s powertrain lineup evolved throughout its production. The initial 2.3L four-cylinder engine with 100 horsepower was considered underpowered for the vehicle’s size. The V6 engines were much more suitable, starting with the 2.8L Cologne V6 (115 hp), quickly followed by the more robust 3.0L Vulcan V6 (145 hp). The pinnacle of Aerostar power came in 1990 with the introduction of the 4.0L Cologne V6, producing up to 160 horsepower. Transmission options included a 5-speed manual, primarily found in cargo and base models until 1995, and more commonly, a 4-speed automatic. A 5-speed automatic was introduced for the final model year. The Aerostar was built on a rear-wheel-drive platform, which contributed to its “truck-like” ride and handling. While the suspension could feel harsh over bumps, the van was noted for being stable and well-controlled. An all-wheel-drive system became an option, enhancing traction in adverse weather conditions.

Ford Aerostar Cargo Pricing and Mileage

When new, the Ford Aerostar Cargo was positioned as an affordable work vehicle. In the mid-1990s, the Manufacturer’s Suggested Retail Price (MSRP) for a cargo model was in the range of $15,000 to $18,000, depending on the year and specific configuration. Fuel efficiency was respectable for its class and time. The 3.0L V6 models typically achieved an EPA rating of around 16-17 MPG in the city and 22-23 MPG on the highway. Real-world mileage reported by owners often aligned with these figures, though driving habits and load would cause variations. Maintenance costs were generally considered reasonable due to the use of shared components with other high-volume Ford vehicles like the Ranger pickup.

Ford Aerostar Cargo Colors, Design, and Dimensions

The exterior design of the Aerostar was one of its most talked-about features, with a sloped, aerodynamic front end that was compared to the Space Shuttle in Ford’s advertising. Color options for the cargo van were typically more subdued and utilitarian than the passenger versions. A range of solid and metallic colors were available over the years, including Oxford White, Black, Vermillion, Medium Graphite Metallic, and Dark Lapis Metallic. The Aerostar was produced in two lengths: the standard version measured 174.9 inches, while the extended version stretched to 190.3 inches. The width was consistently around 71.7 inches, and the height varied slightly between 72 and 74 inches. The wheelbase for all models was 118.9 inches.

Ford Aerostar Cargo Safety Features

Safety features in the Ford Aerostar evolved over its production life. Early models were quite basic by modern standards. However, Ford made notable updates to enhance safety.

• Airbags: A driver-side airbag became a standard feature for the 1992 model year.
• ABS / EBD: Rear-wheel anti-lock brakes were available.
• Electronic Stability Control: This technology was not available during the Aerostar’s production run.
• Crash Test Ratings: The National Highway Traffic Safety Administration (NHTSA) gave later models a 4-star rating for driver-side protection in a frontal crash and a 3-star rating for the passenger side. The Insurance Institute for Highway Safety (IIHS) gave the Aerostar a “Poor” rating in its moderate overlap front test.
• Other advanced safety systems: For 1992, outboard rear-seat passengers in wagon models received three-point shoulder belts. Child safety features like modern anchor systems were not available.

Ford Aerostar Cargo Infotainment and Connectivity

The infotainment and connectivity options in the Ford Aerostar Cargo were rudimentary, reflecting the technology of its era and its primary function as a work vehicle. The standard setup typically included an AM/FM radio, with a cassette player being a common upgrade. Features like a CD player or cruise control were sometimes available as options on higher-end configurations or as part of special packages. The dashboard was redesigned for the 1992 model year, which included more ergonomic climate controls. However, advanced features such as touchscreens, Apple CarPlay, Android Auto, navigation, Bluetooth, and wireless charging were not available during the Aerostar’s production lifespan.

Ford Aerostar Cargo Owner Reviews & Ratings

Owners of the Ford Aerostar Cargo generally hold the vehicle in high regard, particularly for its reliability and durability. Many consumer reviews highlight the van’s longevity, with numerous owners reporting well over 200,000 miles on the original engine and transmission with regular maintenance. The vehicle’s “truck-like” build and rear-wheel-drive platform are often praised for their towing and hauling capabilities. The spacious interior and versatility of the cargo area are also frequent points of praise. Common complaints tend to focus on the somewhat harsh, truck-like ride quality and fuel economy that is modest by today’s standards. Some owners also note that certain repairs can be difficult due to the engine’s placement, making tasks like changing spark plugs a challenge. Despite these issues, a high percentage of owners recommend the vehicle, and it often receives high ratings for reliability and value.

Ford Aerostar Cargo Comparison with Similar Cars

The primary competitors for the Ford Aerostar Cargo were the Chevrolet Astro and GMC Safari vans. Like the Aerostar, the GM twins were rear-wheel-drive and based on a truck chassis, offering substantial towing and hauling capabilities that front-wheel-drive minivans from Chrysler could not match. The Chevy Astro often had an advantage in engine power, with its available 4.3L V6 producing more horsepower than the Aerostar’s offerings. However, the Aerostar was often credited with slightly better fuel economy. In terms of interior space, the Astro generally offered more cargo volume than the Aerostar. The Chrysler minivans (Dodge Caravan, Plymouth Voyager), while popular, targeted a different buyer with their car-like ride and front-wheel-drive platform, sacrificing the rugged utility of the Aerostar and Astro.

Ford Aerostar Cargo Awards and Recognition

• Motor Trend Truck of the Year for 1990: The Ford Aerostar was recognized with this prestigious award, highlighting its capabilities and innovation within the light truck segment.

Interesting Facts about Ford Aerostar Cargo

• The Aerostar’s name and sloped-nosed design were inspired by the Space Shuttle, a theme Ford frequently used in its advertising.
• Despite being over six feet tall, the Aerostar had a drag coefficient of just 0.37, making it more aerodynamic than the Lincoln Mark VII coupe at the time.
• When Ford planned to discontinue the Aerostar after the 1994 model year, a flood of letters from dealers and the public convinced the company to continue its production alongside the new Windstar until 1997.
• The Aerostar was the first minivan in North America to be powered exclusively by V6 engines after 1988 and one of the first to offer all-wheel drive.

Ford Aerostar Cargo Legacy and Influence

The Ford Aerostar carved out a significant niche in the minivan market by offering a more rugged, truck-based alternative to the prevailing car-based models from Chrysler. Its rear-wheel-drive platform and substantial towing capacity appealed to buyers who needed more utility than a standard minivan could provide. The introduction of an all-wheel-drive option was an innovative step for the segment. The Aerostar maintained strong sales throughout its production run, with over 100,000 units sold annually right up until it was discontinued. Its success demonstrated a clear market for a mid-sized van with truck-like capabilities. After its discontinuation, the role of the Aerostar cargo van was not directly filled in Ford’s lineup for many years until the introduction of the Ford Transit Connect.

Ford Aerostar Cargo Global Availability

The Ford Aerostar was primarily manufactured and sold in North America, with the United States and Canada being its main markets. Production was centralized at the St. Louis Assembly Plant in Missouri for its entire run. While the majority of the 2,029,577 Aerostars produced were sold domestically, a limited number of vehicles were exported to other countries outside of North America. It was predominantly produced as a left-hand drive vehicle consistent with its primary markets.

Ford Aerostar Cargo Maintenance and Ownership Costs

Ownership costs for the Ford Aerostar Cargo are generally considered to be low, a factor that has contributed to its long-lasting popularity on the used market. Routine maintenance is straightforward, and the availability of spare parts is good, as the Aerostar shares many mechanical components with the Ford Ranger and Explorer of the same era. Owners have noted the high reliability of the V6 engines and transmissions, which often last for hundreds of thousands of miles with proper care. However, some specific repair jobs, like changing spark plugs, can be labor-intensive due to tight engine bay access. The vehicle’s resale value has depreciated significantly given its age, but it remains a sought-after vehicle for those needing a cheap and dependable work van.

Final Words about Ford Aerostar Cargo

The Ford Aerostar Cargo stands as a testament to a different era of minivans, one where utility and ruggedness were prioritized alongside passenger and cargo hauling. Its unique truck-based platform provided it with towing and payload capacities that set it apart from its front-wheel-drive contemporaries. While its ride could be firm and its features basic by today’s standards, its reputation for durability and longevity is well-earned, as evidenced by the many high-mileage examples still in service. For buyers seeking a practical, no-frills work vehicle with a proven track record of reliability, a well-maintained Aerostar Cargo can still represent an excellent value proposition. Its legacy is that of a tough, versatile, and dependable van that successfully bridged the gap between passenger cars and full-size commercial trucks.