The 2004 Chevrolet Astro has 2 safety recalls and 14 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (4 complaints).
Recalls2safety recalls
Complaints14filed by owners
Crashes · fires1 · 1reported in complaints
Injuries · deaths3 · 0reported in complaints
2004 Chevrolet Astro in an NHTSA crash test
Safety recalls
Fuel system, gasoline
NHTSA recall 06E043000 · May 19, 2006 · 88,303 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 lighting
NHTSA recall 06E026000 · Mar 23, 2006 · 61,944 vehicles · opened 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.
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
2004 Chevrolet Astro
Overall
Not 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)
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 (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
14 / 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, hydraulic Antilock/traction control/electronic limited slip
4
0
1
0
103,500 mi
Vehicle speed control Cruise control
2
0
0
0
—
Electrical system Starter assembly
2
0
1
0
—
Service brakes
2
0
0
0
—
Visibility Glass, side/rear
1
0
0
0
—
Latches/locks/linkages Doors › Latch
1
0
0
0
—
Air bags Frontal
1
1
0
3
—
Parking brake
1
0
0
0
—
Suspension
1
0
0
0
—
Engine
1
0
0
0
—
Fuel system, gasoline Delivery › Fuel pump
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
May 22, 2015 · 70,000 milesVehicle speed control ONCE OR TWICE PER YEAR WHEN USING CRUISE CONTROL, WHEN I TOUCH BRAKE TO DEACTIVATE CRUISE, IT DOESN'T DISENGAGE. I THEN HAVE TO STAND ON BRAKE WITH ALL MY EFFORT TO STOP VAN AND PULL OVER TO PUT IN PARK. ENGINE CONTINUES RACING TIL I TURN KEY OFF. THEN EVERYTHING OK TIL NEXT TIME MAYBE MONTHS LATER. SWITCK ON BRAKE PETAL IS OK. ONCE IN THE WINTER, CRUISE CONTROL PUSHED ME INTO AN INTERSECTION. LUCKILY OTHER TRAFFIC REALIZED I COULDN'T STOP. NO CODES SHOW UP TO IDENTIFY CAUSE. BEEN DOING THIS 4 OR 5 YEARS INTERMITTENTLY. EVEN THO THIS VAN IS 16 YEARS OLD, IT ONLY 6HAS 90000 MILES ON IT. I TRY NOT TO DRIVE IT MUCH BECAUSE OF THIS PROBLEM. MY BEST GUESS IT'S MECHANICAL OR COMPUTER PROBLEM BUT…
May 18, 2006 · 50,500 milesService brakes ANTILOCK BRAKING SYSTEM WARNING LIGHTS AND BRAKE LIGHT CAME ON WHEN I WAS ENTERING THE FREEWAY. THE LIGHTS CONTINUE TO COME ON WHENEVER I AM DRIVING. I HAD IT CHECKED AT CORNING CHEVROLET AND WAS TOLD THE PART ALONE WAS $900 PLUS LABOR TO REPLACE IT. THE BRAKES WORK, BUT NOT THE ANTILOCK SYSTEM INSTALLED BY THE MANUFACTURER.
Apr 16, 2014Service brakes WE LIVE IN THE COUNTRY WITH GRAVEL ROADS. ALL OF OUR CHEVROLET VEHICLES HAVE HAD BRAKE LINES ROT OUT. OUR FORD AND DODGE VEHICLES HAVE NOT. THE CHEVROLET ASTRO VANS WE HAVE EXHIBIT A PROPENSITY FOR THE BRAKE LINE ROTTING OUT OVER THE GAS TANK AS WELL AS THE BRAKE LINES OVER THE FRONT FRAME MEMBERS. THE BRAKE LINES ON 20 YEAR OLD FORD VEHICLES LOOK AS GOOD AS NEW UNDER THE SAME CONDITIONS. MY 1994 CHEVROLET K-3500 PICKUP HAS BLOWN BRAKES LINES DUE TO ROT ALONG WITH THE BACK PART OF THE FRAME THAT RUSTED OUT. I JUST READ WHERE YOU HAVE ADVISED WASHING THE UNDERSIDE OF CHEVROLET VEHICLES SEVERAL TIMES A YEAR. WELL THE LINES ROTTING OUT ON TOP OF THE GAS TANK AND THE FRONT FRAME RAILS WILL NOT…
Jun 14, 2013 · 133,000 milesElectrical system › Starter assembly TL* THE CONTACT OWNS A 2004 CHEVROLET ASTRO. THE CONTACT STATED THAT THE VEHICLE FAILED TO START UNTIL AFTER THREE ATTEMPTS. THE CONTACT SHIFTED INTO DRIVE AND THEN THE VEHICLE LOST ALL POWER. THE CONTACT PUMPED THE ACCELERATOR PEDAL, WAITED TEN MINUTES AND THE VEHICLE RESUMED ITS NORMAL OPERATION. THE FAILURE OCCURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE DEALER DIAGNOSED THE FAILURE AND STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE DEALER ASSURED THE CONTACT THAT AFTER PAYING FOR THE REPAIR, THE FAILURE WOULD BE RESOLVED. THE FUEL PUMP, STARTER, MOTOR MOUNTS, AND GENERATOR WERE ALL REPLACED; HOWEVER, THE FAILURE RECURRED. THE FAILURE MILEAGE WAS…
Sep 19, 2002 · 121,000 milesService brakes, hydraulic IT STARTED WITH MY ABS BRAKE LIGHT COMING ON AND STAYING ON. THEN I STARTED TO ENCOUNTER ANTI LOCK PULSATIONS WHEN I SLOWED DOWN AND COMING TO A STOP, SOME TIMES I COULDN'T EVEN STOP WHEN & WHERE I WANTED. BRAKING DISTANCE STARTED BEING LONGER. THEN SOME TIME LATER I FELT AS THOUGH SOMEONE STUCK A BRICK UNDER MY BRAKE PEDAL BECAUSE NO MATTER HOW HARD I PRESS, I GUARANTEE YOU, I COULDN'T STOP. THANK GOD NO ONE WAS IN FRONT OF ME AS I CRUISED ON THOUGH THE STOP LIGHT! I WAS TOLD THAT MY ABS SENSORS WERE SLOWLY MALFUNCTIONING MOST LIKELY DUE TO CORROSION, A PROVEN DESIGN DEFECT. THEN MY ABS MODULE WILL GET SHORTED, AND THERE IS NO FAIL/SAFE WHEN IT GOES. I WAS TOLD THAT WHEN THE MODULE FAILS,…
Feb 15, 2011 · 86,000 milesService brakes, hydraulic I HAVE AN '04 CHEVY ASTRO VAN WITH ~ 88K MILES. IT IS SERVICED EVERY 3,000 MILES. RECENTLY, MY BRAKES FAILED. THE CAUSE WAS A WORN BRAKE LINE NEAR THE LEFT FRONT WHEEL. IT HAD RUBBED A HOLE IT THE LINE AND I LOST ALL THE BRAKE FLUID. *TR
Mar 30, 2011 · 256,000 milesSuspension AS I WAS DRIVING OVER SOME RAILROAD TRACKS BOTH OF MY FRONT TORSION BARS FAILED AND BROKE. HAD I BEEN TRAVELING ON THE INTERSTATE, IT COULD HAVE BEEN FATAL. FROM MY ONLINE RESEARCH, THIS SAME FAILURE HAS HAPPEND TO THOUSANDS OF OWNERS AND NO RECALL WAS DONE. GM EVEN REDESIGNED THE TORSION BARS BECAUSE OF THE KNOWN DESIGN FLAWS AND IT WILL COST WELL OVER $1,000 TO REPAIR. *TR
Jul 14, 2010 · 131,193 milesParking brake 1. I PARKED MY WIFE'S VAN AT THE NEIGHBOR'S HOUSE BECAUSE GUESTS WERE ABOUT TO ARRIVE. THEIR DRIVEWAY IS ON A SLIGHT INCLINE SO I ENGAGED THE EMERGENCY BRAKE. 2. IT OCCURRED JUST ONCE WITH THE PEDAL GOING COMPLETELY TO THE FLOOR. 3. AFTER CONTACTING GM AND BEING DENIED COMPENSATION DUE TO NO RECALL AND THE AGE OF THE VEHICLE I PURCHASED AND REPLACED THE BROKEN DRIVER SIDE EMERGENCY BRAKE CABLE MYSELF. I BELIEVE THE CAUSE WAS A DESIGN FLAW. I HAVE THE OLD PART IF NEEDED FOR EXAMINATION. THE CABLE WAS COMPLETELY SEVERED DUE TO A CRACK IN THE OUTER SHEATH ALLOWING MOISTURE TO ENTER AND TO DETERIORATE THE CABLE. THE CRACK OCCURRED AT A SEVERE BEND WHERE A BRACKET SECURED THE CABLE TO THE FRAME…
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
