Model year record

1996 Chevrolet Astro recalls & problems

The 1996 Chevrolet Astro has 7 safety recalls and 263 owner complaints on file with NHTSA. The most-reported problem area is suspension (62 complaints).

Recalls7safety recalls

Complaints263filed by owners

Crashes · fires17 · 1reported in complaints

Injuries · deaths12 · 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.

VisibilityApr 28, 2003

Windshield wiper/washer

Recall 03V1590001,755,876 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN MINIVANS, PICKUP TRUCKS, AND SPORT UTILITY VEHICLES WITH CERTAIN MODEL-ENGINE COMBINATIONS, THE WINDSHIELD WIPER MOTOR MAY FAIL DUE TO CRACKED SOLDER JOINTS ON THE CONTROLLER CIRCUIT BOARD. THE WINDSHIELD WIPERS COULD WORK INTERMITTENTLY OR NOT AT ALL.
Risk: IF THIS WERE TO OCCUR DURING BAD WEATHER, DRIVER VISIBILITY WOULD BE REDUCED, WHICH COULD RESULT IN A CRASH.
Fix: DEALERS WILL REPLACE THE WIPER MOTOR CIRCUIT BOARD AND COVER. OWNER NOTIFICATION BEGAN ON JUNE 19, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020, GMC AT 1-800-462-8782, OR OLDSMOBILE AT 1-800-442-6537.

Seat beltsApr 10, 2001

Front › Warning light/devices

Recall 01V123000461,851 vehicles

Problem: VEHICLE DESCRIPTION: MINI VANS. SOME OF THESE VEHICLES FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 208, "OCCUPANT CRASH PROTECTION." THE "FASTEN SAFETY-BELT" AUDIBLE WARNING OCCASIONALLY MAY NOT COME ON OR MAY TERMINATE IN LESS THAN FOUR SECONDS AS REQUIRED BY THE STANDARD.
Risk: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
Fix: DEALERS WILL INSTALL A NEW ALARM MODULE. OWNER NOTIFICATION BEGAN JUNE 27, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR GMC AT 1-800-462-8782.

Child seatJan 20, 1999

Child seat

Recall 99V0090002,090 vehicles

Problem: VEHICLE DESCRIPTION: MINI VANS EQUIPPED WITH INTEGRATED DUAL CHILD SEATS. SOME OF THESE VEHICLES MAY BE MISSING A SEAT BELT RETRACTOR CLUTCH SPRING AND/OR PAWL SPRING IN THE CHILD SEAT. IF THE CLUTCH SPRING WAS MISSING, THE SEAT BELT WOULD LOCK IN THE RETRACTED POSITION AND COULD NOT BE USED. IF THE PAWL SPRING WAS MISSING, THE SEAT BELT RESTRAINT WOULD CONTINUALLY PLAY OUT AND WOULD NOT LOCK.
Risk: THESE CONDITIONS COULD INCREASE THE OCCUPANT'S RISK OF INJURY IN THE EVENT OF A VEHICLE CRASH.
Fix: DEALERS WILL INSPECT THE SEAT BELTS ON THE CHILD SEATS, AND IF NECESSARY, REPLACE THE CHILD SEAT.

Seat beltsApr 8, 1997

Rear/other

Recall 97V05700018,972 vehicles

Problem: THE OUTBOARD SAFETY BELT WEBBING ON THE RIGHT-HAND REAR BUCKET SEAT CAN SEPARATE DURING A VEHICLE CRASH.
Risk: IN THE EVENT OF A CRASH, THE VEHICLE OCCUPANT WOULD NOT BE PROPERLY RESTRAINED AND PERSONAL INJURY COULD RESULT.
Fix: DEALERS WILL INSTALL A PROTECTOR ON THE REAR SEAT CUSHION FRAME.

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

1996 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 AWD (cargo)

16mpg combined

City / highway	15 / 20 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 / 19 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	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,450/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*
SuspensionFront › Springs › Torsion bar; Front	62	2	0	0	81,611 mi
VisibilityWindshield wiper/washer › Motor; Windshield wiper/washer	61	0	1	0	—
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components	39	3	0	4	—
Power trainAutomatic transmission; Driveline › Differential unit	21	0	0	0	—
Fuel system, gasolineDelivery › Fuel pump; Fuel injection system › Injectors	21	0	0	0	—
Engine and engine coolingEngine › Gasoline › Belts and associated pulleys; Exhaust system › Manifold/header/muffler/tail pipe	20	0	0	0	65,000 mi
StructureBody › Door; Frame and members	17	0	0	0	—
SteeringLinkages › Arm › Idler and attachment; Hydraulic power assist › Pump	16	1	0	1	—
Air bagsFrontal	15	13	0	9	106,000 mi
Electrical systemIgnition; Wiring › Interior/under dash	15	0	0	0	140,000 mi
EquipmentAppliance › Air conditioner; Electrical › Radio/tape deck/cd etc.	10	0	0	0	—
Seat beltsFront › Retractor; Front › Buckle assembly	9	3	0	4	—

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

Recent owner complaints

Service brakes
PIN HOLES IN STEEL BRAKE LINES CAUSING COMPLETE BRAKE FAILURE. FORTUNATELY VEHICLE WAS SITTING WHEN BRAKE PETAL WAS APPLIED FOR STARTING. WHEN PRESSING BRAKE TO START VEHICLE, PETAL WENT COMPLETELY TO FLOOR. WHEN CHECKING UNDER VEHICLE TO ANALYZE PROBLEM, PIN HOLES LEAKS WERE OBSERVED IN VARIOUS PLACES FROM FRONT TO REAR IN STEEL LINES. I FEAR WHAT MAY HAVE HAPPENED HAD THE VEHICLE BEEN IN MOTION, AROUND PEDESTRIANS, AND/OR, ON THE ROAD.
Dec 15, 2015 · 120,227 miles
Service brakes
I JUST GOT HOME & WAS BACKING AROUND TO WHERE I PARK WHEN THE BRAKE PEDAL STARTED VIBRATING. I DID MANAGE TO PARK. THE NEXT DAY THE VIBRATING STOPPED WHEN A GRATING NOISE WAS MADE. SUDDENLY THE BRAKE PEDAL CAME WAY UP. IT DOES HAVE SOME BRAKES BUT THEY ARE HARD TO DEPRESS. SUDDENLY MY POWER STEERING IS GONE. THERE WAS NO INDICATION OF PROBLEMS WITH EITHER BEFOREHAND. THIS VAN JUST PASSED INSPECTION IN MID-AUGUST, AND HAS ALWAYS BEEN TAKEN CARE OF. *JS
Aug 31, 2013 · 235,059 miles
Suspension › Front
1996 CHEVY ASTRO LF TORSION BAR BROKE. LUCKILY IT HAPPENED AFTER MY WIFE WENT ON AN 800 MILE TRIP. DEALER REPLACED WITH NEWLY DESIGNED SHORTER BAR. FRONT NOW A LOT LOWER THAN ORIGINAL. DEALER DID NOT REQUIRE OR INSIST THE OTHER ONE BE FIXED AT THIS TIME. THEY ADJUSTED THE CAMBER OF THE WHEEL TO OFFSET THE LOWER LF OF THE CAR. AFTER READING OTHER COMPLAINTS ON THIS BOARD IT WAS CLEARLY A DESIGN FLAW AND SHOULD BE REMEDIED BY GM. THEY KNEW--OR AT LEAST FOUND OUT ABOUT IT--OTHERWISE THEY WOULD NOT HAVE REDESIGNED THE PART. THEY SHOULD PAY FOR REPLACEMENTS ON BOTH SIDES. WHAT DOES IT TAKE? *TR
Apr 26, 2010
Power train › Automatic transmission
1996 CHEVROLET ASTRO WITH TRANSMISSION FAILURE. CONSUMER BELIEVES THAT THE PART THAT FAILED WAS THE SUNSHELL. HE HEARD THAT IF THIS PART FAILS, THE REVERSE AND SOME FORWARD GEARS WILL BE LOST. *KB
Jan 1, 1901
Electrical system › Ignition
TL*THE CONTACT OWNS A 1996 CHEVROLET ASTRO. WHILE DRIVING 55 MPH, THE VEHICLE SHUT OFF WITHOUT WARNING. THE CONTACT FOUND A RECALL NOTICE INSIDE THE VEHICLE FROM WHEN IT WAS PURCHASED. THE RECALL LETTER PERTAINS TO THE IGNITION COIL WIRE. THE PURCHASE DATE WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 180,000.
Jun 25, 2005 · 180,000 miles
Electrical system
ELECTRICAL FAILURE. REPEATED IN A 1996 CHEVY ASTRO. LEADING TO STARTER ENGAGE WHILE ENGINE RUNNING. *NM
Nov 14, 2006 · 132,000 miles
Electrical system › Wiring › Interior/under dash
DT: 1996 CHEVROLET ASTRO. THE VEHICLE BEGAN TO SMOKE ON AUGUST 11, 2005. THE SMOKE WAS COMING FROM THE DASHBOARD. THE VEHICLE WAS BEING DRIVEN WHEN THIS OCCURRED. THE CONSUMER STATED THE SWITCH OR THE PLUG FOR THE REAR AIR CONDITIONER BLOWER MELTED. ALSO, MELTED THE FIRST SIX INCHES OF THE WIRING HARNESS. THE VEHICLE IS STILL DRIVABLE. THE CONSUMER WAS ABLE TO PULL THE VEHICLE OVER AND TURN IT OFF. HE CHECKED TO MAKE SURE THERE WERE NO FLAMES. THIS PROBLEM HAS NOT YET BEEN REPAIRED. *AK
Aug 11, 2005 · 140,000 miles
Suspension › Front › Springs › Torsion bar
THE TORSION BAR SNAPPED IN HALF. THIS BAR WAS INADEQUATE TO THE VEHICLE, AND GM HAS A MODIFIED VERSION FOR THIS. THE BAR BROKE WHILE THE CONSUMER WAS DRIVING THE VEHICLE. THE CONSUMER WAS GOING 10 MPH, WHEN THIS HAPPENED AND THIS CAUSED THE LEFT FRONT TO DROP DOWN ABOUT 8 TO 10 INCHES AND WAS A VIOLENT DROP. THERE WERE NO PROBLEMS BEFORE THIS. THERE WERE NO WRECKS INVOLVED. THE CONSUMER HAD TO TAKE IN TO THE MIDAS DEALER AND HAVE THE TORSION BARS ON THE LEFT AND RIGHT REPLACED WITH THE NEW MODIFIED VERSION. THE FRONT SHOCK ALSO BROKE, AS A RESULT OF THE BAR BREAKING. THE TOTAL OF FIXING THIS WAS $1,000.00 AT THE CONSUMER'S EXPENSE. *TT *SC *JB
May 25, 2005 · 71,000 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 WIPER FAILUREClosedLed to recall 03V159000
AS A RESULT OF THIS, AND THE PRECEDINGINVESTIGATION, RQ99-003, GM HAS EXPANDED THE POPULATION OF SAFETY RECALL 98V-150 (REPLACEMENT OF THE WINDSHIELD WIPER CONTROL MODULE) TO INCLUDE AN ADDITIONAL 1.77 MILLION VEHICLES.INCLUDED ARE VARIOUS 1994-1997 MY M/L VANS, S/T TRUCKS AND SUVS, & C/K TRUCKS AND SUVS.SEE ATTACHED TECHNICAL REPORT FOR DETAILS.
EA02006 · opened May 31, 2002 · closed Jul 23, 2003