A jazzy Sport styling package was introduced for the 1991 Ford Aerostar. Available on the XL and XLT trims, the Sport package featured alloy wheels and silver-tone body accents. Other trim and appearance choices included the two-toned Eddie Bauer trim and a range of classic colors (burgundy, blue, silver, forest) on the standard model. The Extended bodystyle, which had debuted in the previous model year, was a popular choice for the '91 Aerostar: this option provided almost 30 additional cubic feet of cargo volume, for a roomy 170 cubic feet of carrying capacity.
The 1991 Aerostar came standard with rear-wheel drive; all-wheel drive was available as an optional upgrade. The standard engine on the '91 Ford Aerostar was a 145-horsepower Vulcan V6; buyers could upgrade to the 155 horsepower Cologne V6, which put out a solid 230 lb.-ft. of torque. Fuel efficiency was surprisingly good for a midsize minivan; EPA ratings were 17 mpg city, 23 mpg highway. Nobody would be likely to confuse the Aerostar for a performance sports vehicle, even with the Sport package's exterior touches. The Aerostar was popular with suburban soccer moms, though, and the Extended bodystyle was a favorite of tradespeople (especially carpenters), antique dealers, and dog lovers. Conversions for wheelchair users and other people with disabilities were also another market niche to which the Aerostar appealed.
Most of all, the Aerostar sold on its rugged, sturdy presentation, its cargo and passenger capacity, and its relatively affordable price. Buyers overlooked a sometimes stiff suspension and truck-like steering in favor of its durability and toughness.