1989-1991 Ford Aerostar Grille: Fading, Cracks, and the 1991 Sport Package Difference
Learn how to spot a quality used grille, understand the crucial 1991 Sport Package difference, and replace your cracked or faded original.
- For 1991 models, you must verify if the van has the Sport Package, as the standard chrome grille will not fit.
- When buying a used grille, the most important thing to check is the condition of the plastic mounting tabs on the back.
- The Ford emblem is not included with replacement grilles and must be transferred from your old part.
- Replacement is a simple DIY job requiring only a screwdriver and less than 30 minutes.
Symptoms of a Failing Grille
Since the grille is a static body part, "failure" is almost always related to physical damage or cosmetic issues rather than mechanical breakdown. These problems are typically easy to spot.
- Cracked or Broken Plastic: The most common issue is physical damage from minor impacts or road debris. The plastic can become brittle over time, leading to cracks, especially around the mounting points.
- Faded or Peeling Chrome: Years of exposure to sunlight and weather can cause the chrome finish to fade, bubble, or peel away from the plastic base. This is a cosmetic issue but can make the vehicle look worn.
- Broken Mounting Tabs: The grille is held in place by several plastic tabs and screws. If these tabs break, the grille can become loose, rattle, or sit improperly, creating gaps between it and the headlights or bumper.
- Impact Damage: Damage from a front-end collision, even a minor one, can easily break the grille.
Known Issues and Vehicle-Specific Information
The grille for the 1989-1991 Aerostar is a straightforward part, but there is one critical compatibility issue to be aware of.
The 1991 Aerostar Sport Package Exception
For the 1991 model year, Ford offered a "Sport" package. Vehicles with this package used a different grille. While the standard grille is chrome, some evidence suggests the Sport package grille was either argent (silver) or body-colored. The provided vetted data confirms that the standard chrome grille (E99Z8200C / FO1200139) specifically fits 1991 models without the Sport Package. If you have a 1991 Aerostar, you must verify if it has the Sport Package before purchasing a replacement grille.
Pro Tip: Look for other Sport package indicators on a 1991 model, such as unique pinstriping, integrated running boards, or a front air dam, to help determine which grille you need.
Recalls and Technical Service Bulletins (TSBs)
There are no NHTSA recalls or TSBs specifically related to the grille for the 1989-1991 Ford Aerostar. Any recalls for this vehicle pertain to other mechanical or safety systems.
Buying a Used 1989-1991 Aerostar Grille: What to Check
A used OEM grille is often the best value, offering original factory fit and quality. However, you need to inspect it carefully before buying.
- Inspect All Mounting Tabs: This is the most critical inspection point. Carefully check every tab and screw hole on the back of the grille. Even one broken tab can cause the grille to fit poorly or vibrate.
- Check for Cracks and Stress Marks: Look for hairline cracks in the plastic, especially radiating from the screw holes or corners. Pay close attention to the thin bars of the grille, as these can be easily broken.
- Examine the Chrome Finish: Minor scuffs or fading from age can be expected on a used part. However, avoid grilles where the chrome is actively peeling, bubbling, or has deep gouges, as this damage will only get worse.
- Confirm Emblem Provision: This grille has a space for the Ford blue oval emblem, but the emblem itself is a separate part. Do not expect a used grille to come with an emblem. You will likely need to transfer the one from your old grille.
Replacement Difficulty: 1989-1991 Ford Aerostar Grille
Replacing the grille on an Aerostar is a very simple job suitable for any DIYer. The process typically involves removing a few Phillips head screws along the top of the grille and possibly one in the center. Once the fasteners are removed, the grille can be carefully pulled forward to release any lower clips. The entire process usually takes less than 30 minutes with basic hand tools.
Cost Comparison
Prices can vary based on condition and availability.
| Part Type | Estimated Cost |
|---|---|
| New OEM | $150 - $250+ (Very limited availability, may be New Old Stock) |
| New Aftermarket | $90 - $130 |
| Used OEM | $25 - $75 |
| Shop Labor | $50 - $100 (Typically the shop's minimum one-hour charge) |
Part Number Reference
These part numbers are for the standard chrome grille that fits 1989-1991 models (excluding the 1991 Sport Package).
| Part Number | Brand/System |
|---|---|
| E99B-8200-B | Ford (Engineering Number) |
| E99Z8200C | Ford (Service Part Number) |
| FO1200139 | Partslink |
Frequently Asked Questions (FAQ)
What is the difference between the standard and the 1991 Sport Package grille?
The standard grille for 1989-1991 is chrome. The Sport Package grille, available only in 1991, was likely painted argent silver or matched to the body color. They are not interchangeable.
Can I install this grille myself?
Yes, this is a very easy DIY job. It typically requires only a Phillips screwdriver and can be completed in under 30 minutes.
Does the replacement grille come with a new Ford emblem?
No, neither new aftermarket nor used OEM grilles typically include the Ford emblem. You will need to carefully remove the emblem from your old grille and transfer it to the new one.
Will a grille from a 1992 or newer Aerostar fit my 1990 model?
No. The Ford Aerostar received a significant facelift 🎬 Watch: A retrospective on the history of the Ford Aerostar for the 1992 model year, which included a new grille and headlight design. Grilles from 1992-1997 models will not fit the 1989-1991 front end.
Helpful Videos
Technical Specifications
OEM Part Numbers: E99B-8200-B E99Z8200C
Material: Plastic with chrome shell. Emblem: Requires transfer of original emblem.
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Ford Aerostar:
- 🎬 Helpful Videos
- 🛍️ Shop This Part
- Symptoms of a Failing Grille
- Known Issues and Vehicle-Specific Information
- The 1991 Aerostar Sport Package Exception
- Recalls and Technical Service Bulletins (TSBs)
- Buying a Used 1989-1991 Aerostar Grille: What to Check
- Replacement Difficulty: 1989-1991 Ford Aerostar Grille
- Cost Comparison
- Part Number Reference
- Frequently Asked Questions (FAQ)
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