Model year record

1991 Chevrolet Astro recalls & problems

The 1991 Chevrolet Astro has 6 safety recalls and 95 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (51 complaints).

Recalls6safety recalls

Complaints95filed by owners

Crashes · fires12 · 4reported in complaints

Injuries · deaths10 · 0reported in complaints

Safety recalls

Exterior lightingMay 24, 2006

Exterior lighting

Recall 06E04900027,176 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

Fuel system, gasolineMay 19, 2006

Fuel system, gasoline

Recall 06E04300088,303 vehicles

Problem: CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
Risk: THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Fix: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

Exterior lightingMar 23, 2006

Exterior lighting

Recall 06E02600061,944 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

SeatsNov 16, 1993

Seats

Recall 93V187000604,207 vehiclesopened after NHTSA action (ODI)

Problem: THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL BETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEADS TO JOINT LOOSENESS, CAUSING BOLT FATIGUE AND EVENTUAL BOLT FAILURE.
Risk: IF BOLT FAILURE OCCURS TO THE DRIVER'S SEAT, IT WOULDALLOW THE SEAT BACK TO SUDDENLY RECLINE, AND COULD RESULT IN LOSS OF VEHICLECONTROL AND A VEHICLE CRASH WITHOUT PRIOR WARNING.
Fix: DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT FRAME "SOFT" JOINT AND REPLACE THE RECLINER BOLTS.

Seat beltsSep 20, 1991

Front › Anchorage

Recall 91V1640004,842 vehiclesopened after NHTSA action (OVSC)

Problem: SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Risk: VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
Fix: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

Seat beltsJun 14, 1991

Front › Anchorage

Recall 91V102000185 vehiclesopened after NHTSA action (OVSC)

Problem: THE SEAT BELTS FOR THE FRONT AND MID-SHIP SEATS DID NOT REST ON PELVIS AS REQUIRED BY FMVSS 209.
Risk: SEAT BELTS MAY NOT RESTRAIN SEAT OCCUPANT, AND COULDINJURE THE SEAT OCCUPANT IN THE EVENT OF A SUDDEN STOP OR ACCIDENT.
Fix: RELOCATE SEAT BELT ANCHOR BOLTS TO ADJUST BELTS FOR SEAT LOCATIONS.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

1991 Chevrolet Astro

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Astro AWD (cargo)

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $3,950/year to fuel

Astro 2WD (cargo)

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,950/year to fuel

Astro AWD (passenger)

16mpg combined

City / highway	14 / 18 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel

Astro 2WD (passenger)

16mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,200/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Antilock/traction control/electronic limited slip › Abs warning light	51	9	0	2	—
StructureBody › Door; Frame and members	10	0	0	0	—
Electrical systemWiring › Interior/under dash; Alternator/generator/regulator	10	0	4	0	—
Seat beltsFront › Retractor; Front › Webbing	7	3	0	7	—
Power trainDriveline › Driveshaft; Automatic transmission › Lever and linkage › Column shift	7	0	1	0	—
SteeringSteering wheel/handle bar; Linkages › Arm › Idler and attachment	5	0	0	0	—
SeatsFront assembly › Recliner	4	3	0	2	—
TiresTread/belt	4	0	0	0	—
SuspensionRear › Springs; Front › Stabilizer bar	3	0	0	0	—
EquipmentAppliance › Air conditioner	3	0	0	0	—
Latches/locks/linkagesDoors › Latch; Hatchback/liftgate › Lock	3	0	0	0	—
Engine and engine coolingEngine; Exhaust system	2	0	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Service brakes
BEGINNING ABOUT A YEAR AGO, HAVE HAD INTERMITTENT HARD PEDAL WHEN BRAKING. OCCURS RARELY, WITHOUT WARNING. NO ABS LIGHT SEEN BUT SUSPECT POSSIBLE ABS MALFUNCTION. PEDAL DOES NOT PULSATE BUT A FAINT GROWLING, GRINDING, OR BUZZING NOISE IS HEARD. MAY BE ABS MOTOR CYCLING. DURING FAILURE BRAKES ARE BARELY OPERATIVE. USUALLY RETURNS TO NORMAL OPERATION AFTER 2-3 PEDAL PRESSES. SOMETIMES PULLS SHARPLY LEFT, OCCASIONALLY RIGHT, ON BRAKE APPLICATION. THERE IS NO LOSS OF POWER STEERING. OCCURS MOST OFTEN AT FREEWAY SPEED BUT HAS ALSO OCCURRED AT SLOWER SPEEDS. HAS OCCURRED BOTH IN SUDDEN, HARD BRAKING AND IN VERY LIGHT USE. HAVE HAD ALL POWER COMPONENTS, ALL RUBBER HOSES, POWER STEERING PUMP, AND…
Nov 21, 2019 · 258,900 miles
Structure
THE DOOR HANDLES ON BOTH THE PASSENGER AND DRIVER SIDE BROKE OFF. THE SLIDING SIDE DOOR LOCK ENGAGED BEFORE THE DOOR FULLY CLOSED BREAKING THE LOCKING MECHANISM. I HAVE SEEN SEVERAL ASTRO AS WELL AS SAFARI VANS WITH MISSING HANDLES. I AM HAVING TROUBLE FINDING REPLACEMENT DOORS. *TR
Jan 17, 2006
Seat belts › Front › Retractor
THE DRIVER'S SIDE SEAT BELT RETRACTOR FAILED TO RETRACT ON ITS OWN. THE DRIVER WAS ABLE TO CONTACT THE DEALER FOR APPOINTMENT. PLEASE FILL IN ADDITIONAL INFORMATION. *JB
Jan 14, 2005
Seat belts › Front › Retractor
DRIVER'S SIDE AND PASSENGER'S SIDE FRONT AND REAR SEAT BELT RETRACTOR FAILED TO CLICK IN AND HOLD. THIS PROBLEM OCCURRED MORE THAN ONCE AND HAD NOT BEEN RESOLVED. CONSUMER CONTACTED DEALER ON NUMEROUS OCCASIONS, BUT NOTHING WAS RESOLVED. *AK *TC
Dec 1, 2004
Steering › Column
CONSUMER STATED WHILE DRIVING PINS IN STEERING COLUMN SHEARED, CAUSING STEERING TO DROP. CONSUMER HAD TO PULL TO THE SIDE OF THE ROAD AND CALL A TOW TRUCK. CONSUMER HAD VEHICLE TOWED TO HIS HOME, AND REPAIRED THE PROBLEM HIMSELF. ALSO, DOOR HANDLES BROKE OFF, ALL ALMOST AT THE SAME TIME, WITHIN A WEEK APART. CONSUMER REPLACED THEM ON HIS OWN. *AK
Mar 15, 2004
Service brakes, hydraulicCrash
REPEATED TOTAL FAILURE OF BRAKE SYSTEM RESULTING IN THREE SEPARATE REAR END ACCIDENTS OVER 13 YEAR PERIOD. ORIGINAL OWNER. WHEN BRAKING FOR SUDDEN EMAERGENCY STOP,AFTER INITIAL BRAKING BEGINS, BRAKE PETAL GOES DOWN TO FLOOR AND BRAKES COMPLETELY RELEASE, RESULTING IN NO BRAKE STOPPAGE OF VECHICLE AND SUSEQUENT REAR ENDING OF VEHICLE IN FRONT. DEALER DENIES SYTEM RECORD OF BRAKE FAILURE AFTER SECOND OCCURRANCE. WHEN HEARD ABOUT RECALL, DEALER SAYS DOES NOT APPLY IN CANADA, AND NOT APPLICABLE TO THE 1991 MODEL YEAR.
Oct 15, 2003
Unknown or other
PAINT PEELING OFF TRUCK ALL OVER
Sep 15, 2003
Interior lighting
THE BACK DOUBLE DOOR WILL NOT OPEN ANYMORE. I CAN NOT GET INTO THE VAN TO PLACE MY SONS WHEEL CHAIR INTO IT. THE SPACE IN THE REAR WAS THE REASON WHY I PURCHASED THE VEHICLE. THE SIDE DOOR WILL NO LONGER LOCK, AND THE INTERIOR LIGHT WILL NOT COME ON WHEN THE DOOR IS OPEN. *TS *NLM **DIMSII IVOQ ENTRY POSTED AFTER 12-12-02 CUT OVER TO ARTEMIS**770142
Nov 26, 2002

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

INSTRUMENT PANEL/DASH ELECTRICAL FIREClosed
ALLEGED ELECTRICAL FIRES MAY OCCUR IN THE DASH AREA WHILE THE SUBJECT VEHICLES ARE BEING OPERATED OR WHILE PARKED.
PE97025 · opened Jun 12, 1997 · closed Nov 26, 1997
SEAT BACK BOLT BREAKAGEClosedLed to recall 93V187000
There is no summary currently available
EA92022 · opened Jun 24, 1992 · closed Nov 19, 1993
APV FIRESClosed
APV FIRES
DP92012 · opened Jun 9, 1992 · closed Jun 25, 1992
BRAKE FAILUREClosed
===
EA91028 · opened Jun 10, 1991 · closed Jun 30, 1992
BRAKE FAILUREClosed
There is no summary currently available
PE91052 · opened Feb 22, 1991 · closed Jun 10, 1991