Model year record

2003 Chevrolet Astro recalls & problems

The 2003 Chevrolet Astro has 3 safety recalls and 62 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (24 complaints).

Recalls3safety recalls

Complaints62filed by owners

Crashes · fires3 · 3reported in complaints

Injuries · deaths4 · 0reported in complaints

2003 Chevrolet Astro in an NHTSA crash test — NHTSA crash test

Safety recalls

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.

SuspensionSep 12, 2003

Front › Control arm › Lower ball joint

Recall 03V32800041,477 vehicles

Problem: CERTAIN MINIVANS HAVE AN INTERFERENCE CONDITION BETWEEN THE LOWER BALL JOINT RUBBER BOOT AND THE STEERING KNUCKLE (BOTH LEFT/RIGHT SIDES), WHICH COULD RESULT IN CUTTING OF THE BOOT THAT IS INTENDED TO SEAL THE BALL JOINT. IF THE LOWER BALL JOINT BOOT WERE CUT, CONTAMINATION FROM THE ROAD (SALT, DIRT, WATER, ETC.) COULD ENTER THE BALL SOCKET AREA OF THE BALL JOINT CAUSING THE JOINT TO WEAR OUT TOO QUICKLY.
Risk: THE STEERING KNUCKLE COULD SEPARATE FROM THE LOWER CONTROL ARM, DROPPING DOWN THE AFFECTED CORNER OF THE VEHICLE. THE COIL SPRING WOULD PUSH THE CONTROL ARM DOWN INTO CONTACT WITH THE GROUND, CREATING A DRAG THAT WOULD SLOW THE VEHICLE. THE DRIVER COULD HAVE DIFFICULTY IN MAINTAINING THE DIRECTIONAL CONTROL OF THE VEHICLE. IN ADDITION, THE AFFECTED WHEEL ASSEMBLY COULD SEPARATE FROM THE VEHICLE IF FORCES RESULTING FROM THE WHEEL'S DRAGGING ACTION WERE SUFFICIENT TO FRACTURE THE TIE ROD END AND UPPER BALL JOINT CONNECTIONS. SEPARATION OF THE WHEEL ASSEMBLY WOULD ALSO SEVER THAT WHEEL'S HYDRAULIC BRAKE HOSE, RESULTING IN LOST BRAKING PERFORMANCE FROM THE FRONT BRAKE SYSTEM. VEHICLE STOPPING DISTANCE WOULD INCREASE, WHICH COULD RESULT IN A CRASH.
Fix: DEALERS WILL REPLACE THE STEERING KNUCKLES. OWNER NOTIFICATION IS EXPECTED TO BEGIN ON APRIL 8, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

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

2003 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 / 21 mpg
Fuel	Regular Gasoline

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

Astro 2WD (passenger)

16mpg combined

City / highway	14 / 19 mpg
Fuel	Regular Gasoline

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

Astro 2WD (cargo) Conversion

15mpg combined

City / highway	13 / 18 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel

Astro AWD (cargo)

15mpg combined

City / highway	14 / 18 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,450/year to fuel

Astro AWD (cargo) Conversion

14mpg combined

City / highway	12 / 16 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

Astro AWD (passenger)

14mpg combined

City / highway	12 / 16 mpg
Fuel	Regular Gasoline

4.3 L · 6 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/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 › Disc › Rotor	24	1	2	0	49,000 mi
Electrical system12v/24v/48v battery › Cables; Wiring › Interior/under dash	10	0	2	2	79,123 mi
Power trainAutomatic transmission; Automatic transmission › Control module (tcm/pcm/tecm)	9	0	0	0	31,000 mi
SuspensionFront › Control arm › Lower ball joint; Front › Control arm › Upper ball joint	8	0	0	0	78,400 mi
SteeringRack and pinion; Linkages › Knuckle › Spindle › Arm	6	1	1	1	50,000 mi
Service brakes	5	0	0	0	80,000 mi
Latches/locks/linkagesDoors › Latch	3	0	0	0	—
Engine and engine coolingCooling system; Engine	3	0	1	0	—
VisibilityWindshield wiper/washer; Rearview mirrors/devices › Exterior	2	0	0	0	—
Vehicle speed controlCables	2	0	0	0	—
Exterior lightingBrake lights › Switch; Brake lights	2	0	0	0	—
StructureFrame and members › Underbody shields	1	0	0	0	—

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

Recent owner complaints

Suspension
TL* THE CONTACT OWNS A 2003 CHEVROLET ASTRO. THE CONTACT WAS MADE AWARE BY AN INDEPENDENT MECHANIC THAT HIS VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V328000 (SUSPENSION) WHILE PERFORMING ROUTINE MAINTENANCE ON THE VEHICLE. THE VEHICLE WAS DIAGNOSED WITH A FAULTY STEERING KNUCKLE AND LOWER BALL JOINTS. MYRTLE BEACH CHEVROLET (1785 US-501, MYRTLE BEACH, SC 29577) AND THE MANUFACTURER WERE MADE AWARE OF THE ISSUES. THE CONTACT WAS INFORMED THAT THE PARTS WERE NO LONGER MADE AND THERE WERE NO AFTER MARKET PARTS AVAILABLE. THE FAILURE MILEAGE WAS 392,000.
Apr 30, 2021 · 392,000 miles
Electrical system
FRONT SUSPENSION ISSUES, ELECTRICAL GAUGES, REPLACEMENT OF FUEL TANK PUMP, DOOR LATCHES FAILING TO OPEN ON SLIDING SIDE DOOR MAKING EXITING OF VEHICLE IMPOSSIBLE, RECALL OF 02V328000 UNABLE TO BE CONFIRMED AS HANDLED BY ANY DEALERS.
Sep 12, 2017 · 118,000 miles
Air bagsCrash1 injury
2003 CHEVROLET ASTRO CARGO VAN AIR BAG DID NOT DEPLOY AT TIME OF COLLISION. ASTRO VAN WAS HIT ON PASSENGER SIDE, FRONT WHEEL WELL & BUMPER. DRIVER WHO HIT VAN WAS EXCEEDING SPEED LIMIT, APPROXIMATELY DOING CLOSER TO 40 MPH IN A 25 MPH ZONE WHEN THEY HIT OUR VAN. WE WERE JUST STARTING TO PROCEED AFTER A STOP SIGN, BARELY DOING 10 - 15 MPH. THE ASTRO VAN WAS DRAGGED APPROXIMATELY 6-7 FEET INTO THE INTERSECTION. THE AIR BAG NEVER DEPLOYED, DRIVER WAS INJURED RIGHT SIDE BACK & RIBS BRUISED AND POSSIBLE CONCUSSION HEAD INJURY TO LEFT SIDE OF HEAD DUE TO FORCE OF IMPACT.
Nov 5, 2014 · 206,000 miles
Service brakes
I WAS DRIVING PULLING A TRAILER ON THE FREEWAY WHEN SUDDENLY THE TRAFFIC STOP. I APPLIED THE BRAKES AT A SAFE DISTANCE WHEN SUDDENLY MY BRAKES WHEN ALL THE WAY TO THE FLOOR I APPLIED THE EMERGENCY BRAKES AND STOP. I HAD TO GO THRU THE EMERGENCY LANE. I TOLD MY SON TO PUSH THE BRAKE PEDAL WHILE I WAS UNDERNEATH AND THE BRAKE LINES BROKE. THEY WHERE ALL RUSTED OUT. I HAD TO GET A WRECKER TO TAKE IT HOME.IF YOU NEED TO SEE MY VAN CALL ME SO YOU CAN SEE THE BRAKE LINES. *TR
May 23, 2014 · 96,500 miles
Service brakes
MY SPOUSE WAS DRIVING AND WE WERE STOPPED AT A YARD SALE. WE RETURNED TO THE VEHICLE AND STARTED TO BACK OUT WHEN SHE NOTICED THE STEERING WHEEL WAS EXTREMELY HARD TO TURN. THEN WHEN SHE WANTED TO STOP THE VEHICLE THE BRAKES WERE EXTREME HARD TO OPERATE. AFTER SOME RESEARCH WE LEARNED OF HUNDREDS OF BRAKE MALFUNCTIONS ON SIMILAR VEHICLES AND OTHER CARS THAT USE SIMILAR BRAKE BOOSTER TECHNOLOGY. *TR
Apr 5, 2014 · 150,000 miles
Service brakes
I AM COMPLAINING OF THE SAFETY ISSUES REGARDING THE ABS COMPUTER SYSTEM. I HAVE PUT MY VEHICLE IN THE SHOP TO BE CHECKED OUT BY A FEW CAR REPAIR FACILITIES AND ALL HAVE SAID THE SAME THING MY ABS CPU. MY VAN IS HESITATING TERRIBLY AND CAUSING THE VAN TO NOT ACCELERATE PROPERLY. I HAVE NEARLY BEEN IN THREE ACCIDENTS SINCE THE PROBLEM HAS BEEN OCCURRING. I HAVE ALSO DONE SOME RESEARCH ON THIS ISSUE VIA INTERNET AND FOUND THAT MANY PEOPLE ARE HAVING THE SAME PROBLEM ACROSS THE USA. AND GM IS BLAMING IT ON THE WEATHER CONDITIONS IN THE NORTH BUT THE PROBLEMS ARE HAPPENING TO ASTRO VANS(2003) ACROSS THE ENTIRE US. THIS IS A PROBLEM THAT SHOULD BE ADDRESSED AS SOON AS POSSIBLE.. THE CONTACT…
Oct 9, 2013 · 50,000 miles
Service brakes
TL* THE CONTACT OWNS A 2003 CHEVROLET ASTRO VAN. THE CONTACT STATED THAT THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOOR WHILE MAKING A LEFT TURN. THE CONTACT ALSO STATED THAT THE VEHICLE FAILED TO START WHEN THE VEHICLE WAS PARKED AND THE WHEELS WERE TURNED TO THE LEFT. A MECHANIC LOOKED UNDER THE VEHICLE AND FOUND THAT THE WIRING HARNESS THAT WAS LOCATED NEAR THE FRONT PASSENGER SIDE TIRE HAD BURNED OUT. THE VEHICLE WAS TAKEN TO THE DEALER BUT THE CONTACT WAS UNSURE OF WHAT WOULD BE REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN BUT THE CURRENT MILEAGE WAS 67,000. *TR
Jul 14, 2004 · 67,000 miles
Service brakes
COMPLETE BRAKE FAILURE DUE TO RUSTING BRAKE LINES. THE PREVIOUS DAY THIS VEHICLE WAS PULLING A SMALL TRAILER ON A MICHIGAN INTERSTATE HIGHWAY. THE FOLLOWING DAY IT WAS PARKED IN MY DRIVEWAY AND A WET AREA WAS VISIBLE ON THE CONCRETE. IT WAS BRAKE FLUID ON THE GROUND THAT HAD DRIPPED FROM THE RUSTED BRAKE LINE AND DRAINED THE MASTER CYLINDER RESERVOIR. I DISCOVERED THIS WHEN MOVING THE VEHICLE TO TRY AND DETERMINE THE CAUSE OF THE FLUID LEAK. THE BRAKE LINE HAD COMPLETELY RUSTED THROUGH! FORTUNATELY THIS DID NOT HAPPEN THE PREVIOUS DAY AS IT COULD EASILY HAVE BEEN FATAL. THE VEHICLE WAS TOWED TO THE GM DEALERSHIP. THERE ARE NO REPLACEMENT PARTS FOR THE BRAKE LINES AND NONE ARE AVAILABLE IN…
Aug 13, 2012 · 80,000 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.