Model year record

1994 Chevrolet Astro recalls & problems

The 1994 Chevrolet Astro has 6 safety recalls and 328 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (105 complaints).

Recalls6safety recalls

Complaints328filed by owners

Crashes · fires43 · 3reported in complaints

Injuries · deaths42 · 1reported 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).

Fuel system, gasolineMay 18, 2006

Delivery › Hoses, lines/piping, and fittings

Recall 06E0410007,800 vehicles

Problem: CERTAIN R&B, INC. CENTRAL MULTIPORT FUEL INJECTION (CMFI) FUEL RETURN LINES, MODELS HELP 55163, NAPA BALKAMP 700-3270, AND THE CONNECTION 2560001, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE VEHICLES LISTED ABOVE. THE FUEL RETURN LINE HAS A MECHANICAL BLEED VALVE WHICH WAS NOT INSTALLED AT THE PROPER TORQUE.
Risk: A FUEL LEAK CAN OCCUR AT THE VALVE, POSSIBLY RESULTING IN A FIRE.
Fix: R&B, INC. WILL NOTIFY OWNERS AND AT THE CUSTOMERS REQUEST, EITHER REPLACE THE FUEL LINE OR OFFER A FULL REFUND. THE RECALL BEGAN ON MAY 4, 2006. OWNERS MAY CONTACT R&B, INC. AT 215-712-5330.

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.

SeatsSep 14, 1994

Front assembly › Head restraint

Recall 94V177000381 vehiclesopened after NHTSA action (OVSC)

Problem: THE FRONT DRIVER AND PASSENGER SEAT BACK HEIGHT DOES NOT CONFORM TO THE REQUIREMENTS OF FMVSS NO. 202, "HEAD RESTRAINTS."
Risk: CONSEQUENCE OF NON-COMPLIANCE: SEAT OCCUPANTS ARE SUBJECT TO INCREASED RISK OF INJURY IN THE EVENT OF A SUDD STOP OR ACCIDENT.
Fix: SHERRY DESIGNS WILL PROVIDE AN ATTACHABLE HEADREST FOR THE DEALER OR CUSTOMER TO ADD TO THE SEATS.

EquipmentMay 9, 1994

Other › Labels

Recall 94V0870002,255 vehiclesopened after NHTSA action (OVSC)

Problem: THE MANUFACTURER'S CERTIFICATION LABEL AND/OR THE DRIVER AIR BAG ADVISORY LABEL MAY BE MISSING FROM THE VEHICLES, WHICH DOES NOT CONFORM TO THE REQUIREMENTS OF 49 CFR 567.
Risk: CONSEQUENCE OF NON-COMPLIANCE: OWNERS OF VEHICLE WOULD BE UNAWARE OF THE LOAD CAPACITY OF THE VANS, THE VAN BUILD DATE, AND WOULD NOT HAVE ANY ASSURANCE THAT THE VANS MEET THE FEDERAL MOTOR VEHICLE SAFETY STANDARDS.
Fix: THE LABELS WILL BE FURNISHED TO OWNER'S FOR INSTALLATION ON THE VEHICLES.

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

1994 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 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 2WD (cargo)

17mpg combined

City / highway	15 / 20 mpg
Fuel	Premium Gasoline

4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,850/year to fuel

Astro AWD (cargo)

16mpg combined

City / highway	15 / 19 mpg
Fuel	Premium Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $5,150/year to fuel

Astro 2WD (passenger)

16mpg combined

City / highway	14 / 19 mpg
Fuel	Premium Gasoline

4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,150/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

Astro AWD (passenger)

15mpg combined

City / highway	14 / 17 mpg
Fuel	Premium Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $5,500/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; Foundation components	105	15	0	3	140,850 mi
VisibilityWindshield wiper/washer › Motor; Windshield wiper/washer	88	3	0	0	113,961 mi
SuspensionFront › Springs › Torsion bar; Front	41	1	0	3	151,975 mi
Air bagsFrontal	28	26	0	26	—
Engine and engine coolingEngine › Gasoline; Exhaust system › Emission control › Gas recirculation valve (egr valve)	17	0	1	0	102,000 mi
Electrical systemWiring › Interior/under dash; Alternator/generator/regulator	15	1	2	0	—
SteeringLinkages › Arm › Idler and attachment; Hydraulic power assist system	13	0	0	1	—
Power trainAutomatic transmission; Driveline › Differential unit	12	0	0	1	—
Seat beltsFront › Buckle assembly; Rear/other	11	1	0	4	—
Fuel system, gasolineFuel injection system; Delivery › Fuel pump	10	0	0	0	—
SeatsFront assembly › Recliner	9	1	0	6	—
EquipmentAppliance › Air conditioner	8	1	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, hydraulicCrash1 injury
ON NOVEMBER 21ST, 2011, I WAS DRIVING MY ASTRO VAN ON A STRAIGHT ROAD. THE VEHICLE IN FRONT OF ME APPLIED THEIR BRAKES. I ALSO APPLIED MY BRAKES, BUT MY FOOT SLIPPED OFF THE BRAKE PEDAL. I ATTEMPTED 4 TIMES IN A PANICKED STATE TO TRY AND RE-APPLY MY BRAKES WITH NO SUCCESS. I STRUCK THE VEHICLE IN FRONT OF ME. AFTER CONSIDERING WHAT HAD HAPPENED THAT DAY AND LOOKING AT THE BRAKE PEDAL SIZE IN THE VEHICLE IT IS NO WONDER I COULDN'T READILLY RE-APPLY THE BRAKE. I MEASURED THE BRAKE PEDAL SURFACE AREA. IT IS APPROXIMATELY 4 SQ. INCHES. I HAVE SINCE BEEN LOOKING AT OTHER VEHICLES AND THE SIZE OF THEIR BRAKE PEDAL SURFACE AREA. I HAVE YET TO DATE FOUND SUCH A SMALL BRAKE PEDAL IN ANY OTHER…
Nov 21, 2011 · 162,000 miles
Power train
TL*THE CONTACT OWNS A 1994 CHEVROLET ASTRO VAN. THE CONTACT STATED THAT WHILE DRIVING, THE ENTIRE DIFFERENTIAL UNIT FELL FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE THE TRANSMISSION PIN WAS REPLACED. THE CONTACT WAS WAITING TO FIND OUT IF THE DIFFERENTIAL COULD BE REPAIRED. THE CONTACT CALLED THE MANUFACTURER WHO OFFERED NO ASSISTANCE. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 27,000. UPDATED 01/06/11 *BF THE CONSUMER STATED THE PREVIOUSLY, TRANSMISSION PAN HAD TO BE REPLACED AS IT WAS LEAKING DUE TO RUST. THE CONSUMER STATED NO FURTHER REPAIRS HAVE BEEN MADE AS THE VEHICLE WAS CONSIDERED NOT WORTH FIXING AFTER ASSESSING THE AMOUNT OF DAMAGE DO THE…
Oct 5, 2010 · 27,000 miles
Visibility
I HAVE A 1996 CHEVY ASTRO VAN. DURING A HEAVY RAIN,WITH THE WIPERS ON HIGH THE WIPERS STOPPED WORKING. *TR
Aug 10, 2008 · 130,000 miles
Engine and engine cooling › Engine
TL*THE CONTACT OWNS A 1994 CHEVROLET ASTRO. WHILE DRIVING LESS THAN 50 MPH, THE ALTERNATOR BRACKET FAILED. WITHIN A THREE MONTH PERIOD, THE BRACKET HAS FAILED TWICE. THE CONTACT ATTEMPTED TO FIND A REPLACEMENT COMPONENT AT A JUNKYARD AND WAS INFORMED BY THE JUNKYARD DEALER THAT HE RECEIVED NUMEROUS REQUESTS FOR THAT PARTICULAR COMPONENT DUE TO FREQUENT FAILURES. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS OVER 100,000 AND CURRENT MILEAGE WAS 105,000.
Oct 15, 2008 · 100,000 miles
Suspension › Front
THIS IS THE SECOND TIME I WILL HAVE TO REPLACE THE TORSION BAR ON THIS 1994 CHEVY ASTRO AWD VAN. THE FIRST TIME WAS ABOUT 4 YEARS AGO. I HAVE DONE A SEARCH AND THERE ARE HUNDREDS IF NOT THOUSANDS OF REPORTS OF THE TORSION BARS FAILING WITHOUT WARNING, RESULTING IN BOTTOMING OF THE SUSPENSION. FORTUNATELY, IT FAILED WHEN I WAS PARKED BOTH TIMES IT HAS FAILED BUT COULD HAVE BEEN DEVASTATING IF I WAS ON THE HIGHWAY. *TR
Jul 5, 2008 · 163,951 miles
Suspension › Front
TL*THE CONTACT OWNS A 1994 CHEVROLET ASTRO. BEFORE THE CONTACT ATTEMPTED TO DRIVE HER VEHICLE, SHE NOTICED THAT THE DRIVER'S SIDE WAS LAYING ON THE GROUND. SHE DID NOT NOTICE ANY DIFFERENCES IN THE VEHICLE PRIOR TO THE FAILURE. SIX YEARS AGO, THE CONTACT NEEDED TO HAVE THE TORSION BAR REPLACED AT 80,000 MILES. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 180,000.
Jun 11, 2008 · 180,000 miles
Suspension › Front
WE OWN A 1994 CHEVY ASTRO VAN. FORTUNATELY, IT WAS SITTING IN OUR DRIVEWAY WHEN ONE OF THE TORSION BARS BROKE, DROPPING THE VAN DOWN ONTO THE FRONT LEFT TIRE. IF THIS HAD HAPPENED WHILE WE WERE DRIVING THE VAN WITH OUR FAMILY, IT COULD HAVE BEEN DISASTROUS. TWO DAYS LATER, THE OTHER TORSION BAR BROKE, AGAIN IN OUR DRIVEWAY. IN LOOKING AT THE WAY THE TORSION BAR IS MOUNTED TO THE CROSS MEMBER, IT APPEARS THAT A MANUFACTURE DEFECT CREATED A PROBLEM WHERE SNOW, SALT, RAIN AND DIRT ACCUMULATED INTO THE CYLINDER SHAPED TUBE THAT THE BAR IS MOUNTED INTO, TOWARDS THE REAR OF THE VEHICLE. THE TORSION BAR, MADE OF SPRING STEEL, RUSTED AND BROKE IN TWO. THE TORSION BAR IS PART OF THE SUSPENSION THAT…
Jul 21, 2006 · 126,112 miles
Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittings
DT: THE CONSUMER STATED THAT WHILE DRIVING AT 30 MPH THE METAL BRAKE LINE HAD BURST ON THE LEFT FRONT DRIVER'S SIDE OF THE VAN WITHOUT ANY PRIOR INCIDENT. THE LINE BROKE AS THE BRAKE PRESSURE WAS APPLIED. THE CONSUMER AVOIDED A COLLISION AND WAS ABLE TO PULL OVER. THE BRAKE PEDAL WAS PUSHED ALL THE WAY TO THE FLOOR. THE CONSUMER'S HUSBAND DROVE THE VEHICLE HOME WITH THE EMERGENCY BRAKE APPLIED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP WHO CONFIRMED THE PROBLEM WITH THE BRAKE LINES. THE MECHANIC REPLACED THE ENTIRE BRAKE LINE. SINCE THE REPAIR, THERE HAVE BEEN NO FURTHER PROBLEMS. *AK (11/29/05) *SC
Oct 15, 2005 · 140,000 miles

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

WINDSHIELD WIPERClosed
RQ99003 · opened Mar 8, 1999 · closed May 31, 2002