RoadVitals

1991 Chevrolet Astro

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
95
Latest Dec 2, 2019
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
6
Latest May 24, 2006
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
5
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
16
10 injuries, 0 deaths reported

Overview

Our database contains 95 NHTSA owner-reported complaints for the 1991 Chevrolet Astro, most frequently naming the brakes, interior & seats and body & structure categories. 6 safety recalls have been issued covering this model year; 5 NHTSA investigations name it; and 9 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

6 campaigns cover this model year

View all 6

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
06E049000

EXTERIOR LIGHTING

May 24, 2006
27,176 units potentially affected
The defect: 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.
The risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
The remedy: 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.
CK MOTORSPORT, INC.View on NHTSA.gov
06E043000

FUEL SYSTEM, GASOLINE

May 19, 2006
88,303 units potentially affected
The defect: 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.
The 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.
The remedy: 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).
HONEYWELL INTERNATIONAL, INC.View on NHTSA.gov
06E026000

EXTERIOR LIGHTING

Mar 23, 2006
61,944 units potentially affected
The defect: 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.
The risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
The remedy: 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.
PRO-A MOTORS, INC.View on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

PE97025ClosedPreliminary Evaluation

INSTRUMENT PANEL/DASH ELECTRICAL FIRE

Opened Jun 12, 1997
Closed Nov 26, 1997

ALLEGED ELECTRICAL FIRES MAY OCCUR IN THE DASH AREA WHILE THE SUBJECT VEHICLES ARE BEING OPERATED OR WHILE PARKED.

ELECTRICAL SYSTEM
EA92022ClosedEngineering Analysis

SEAT BACK BOLT BREAKAGE

Opened Jun 24, 1992
Closed Nov 19, 1993

There is no summary currently available

SEATSLed to recall 93V187000
DP92012ClosedDefect Petition

APV FIRES

Opened Jun 9, 1992
Closed Jun 25, 1992

APV FIRES

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
EA91028ClosedEngineering Analysis

BRAKE FAILURE

Opened Jun 10, 1991
Closed Jun 30, 1992

===

SERVICE BRAKES, HYDRAULIC

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 95
Brakes
Filed Dec 2, 2019

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 BOTH FRONT WHEEL BRAKE COMPONENTS PROFESSIONALLY REPLACED. VEHICLE HAS FRONT DISC/REAR DRUM AND HYDROBOOST. MECHANIC USUALLY CANNOT DUPLICATE THE PROBLEM BUT HAS DONE SO ONCE AND HAS NO EXPLANATION FOR IT. SEEKING TO LEARN POSSIBLE REASONS AND CURE.

NHTSA ID
11286510
Incident
Nov 21, 2019
Mileage
258,900 mi
Body & structure
Filed Jan 31, 2009

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

NHTSA ID
10257005
Incident
Jan 17, 2006
Seat belts
Filed Jan 14, 2005

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

NHTSA ID
10107408
Incident
Jan 14, 2005
Seat belts
Filed Dec 17, 2004

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

NHTSA ID
10097865
Incident
Dec 1, 2004
Body & structureSteering
Filed Mar 15, 2004

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

NHTSA ID
10063227
Incident
Mar 15, 2004
Brakes
Filed Jan 15, 2004
Crash reported

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.

NHTSA ID
10071394
Incident
Oct 15, 2003
Filed Jan 15, 2004

PAINT PEELING OFF TRUCK ALL OVER

NHTSA ID
10069111
Incident
Sep 15, 2003
Body & structureInterior & seats
Filed Nov 26, 2002

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

NHTSA ID
10009407

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

PIT-3665-A

SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES

GENERAL MOTORS: ON ALL 1988-2009 FULL SIZE CHEVROLET/GMC PICKUPS, UTILITIES AND VANS, THE BRAKE PEDAL WILL MOVE DOWN OR SELF APPLY DURING FULL LOCK TURNS OR NEAR FULL LOCK TURNS. CHEVROLET ASTRO AND GMC SAFARI VANS; HUMMER 2 ARE INCLUDED. *PE UPDATED 5/24/11. *PE

020730024A

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT

DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT

01667

VISIBILITY

WINDOW REGULATOR MOTOR DOES NOT FIT. *TT

990730016A

POWER TRAIN

DIAGNOSTIC INFORMATION FOR INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP, BUSY/CYCLING TCC OR NOISY COOLING FAN. *TT

RCL/91C50

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

RECALL 91-C-50 - GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 CHEVRTOLET C/K TRUCKS, M/L AND G VANS EQUIPPED WITH 4.3L ENGINES [RPO LB4 OR RPO LU2 (M VAN ONLY)] MAY BE EMITTING NON-METHANE HYDROCARBONS (NMHC) IN EXCESS OF CALIFORNIA EMISSIONS STANDARDS. CALIFORNIA EMISSIONS STANDARDS WERE ESTABLISHED TO PROTECT THE PUBLIC HEALTH AND WEALFARE FROM DANGERS OF AIR POLLUTION. EXCESS EMISSION OF NMHC MAY CAUSE A VEHICLE TO FAIL STATE MANDATED EMISSION TESTS. TO CORRECT THIS CONDITION, DEALERS ARE TO INSTALL A NEW OXYGEN SENSOR. *TW

376105

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

COLD ENGINE KNOCK. *TW

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Chevrolet Astro by model year
YearComplaintsRecallsInvestigationsIssue Index
2005920—
2004142048.0
2003623050.3
2002703157.1
2001913156.9
20001752052.9
19991334054.3
19982416054.3
19973607156.5
19962637155.0
19954467363.5
19943286160.9
19931355053.3
19921325162.6
1991Viewing956566.1
1990687667.9
1989576160.9
1988565763.5
1987295763.2
1986234665.4
1985565—
1984111—
1983010—
1976001—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.