I just replaced the water pump at 152,000 miles.
The front power windows have been a problem, but it has been the cheap plastic buttons that operate the windows and not the window motors. The buttons crack easily and do not engage the motors properly. I used J.B. Weld to strengthen the plastic buttons and this solved the problem. The channel gaskets in the windows need to be lubricated in order that the windows slide up and down properly. I have had some rust problems in the rocker panel areas below the front doors and on the drivers side down in the lower areas. The paint job is not high quality and I will need to repaint this vehicle in the near future.
I have replaced brake pads periodically on the front disk brakes, but I see this as routine maintenance.
I do have slight irregular shifting in the lower gears of my automatic transmission, but it still shifts reasonably well.
This is a well-designed, roomy van and I love it. It is a pleasure to drive. It holds 7 passengers comfortably and with the rear seats out it can hold an amazing amount of items. It is probably the most versatile vehicle that I have ever owned. The motor (3.0) runs perfectly and my mileage is 22 - 25 on the highway. The interior is well laid out and has quality carpeting and upholstery. The captain seats are very comfortable and the Aero star is a good cruiser on long trips. I do wish that the passenger seat moved back and forth and was not stationary.
Everything works on this van even after 150 K of miles. I am impressed! (cruise control, wipers- (front and back), windshield washers, heater, a.c., radio, power windows, interior lights, etc.)
It has a solid "truck-type" body and is well built with very few rattles. I previously had a Ford van and it was loose, noisy, not economical, bulky, and hard to drive and park. My Aero star is tight, quiet, has good mileage, and is a dream to drive and park.
I also like the looks of the Aero star. With the sloped front windshield and the neat, boxy exterior, it suits my needs perfectly. I am a professional person and I drive my clients around with pride in this vehicle; yet, on weekends I can easily haul 4' by 8' sheets of plywood in my Aero star. After driving this vehicle for some time, I have regained my faith in Ford products again. Thank you Uncle Henry for producing a fine vehicle.