1994 Chevrolet Astro Suspension Problems

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

NHTSA ID

10233701

Incident

Jul 5, 2008

Mileage

163,951 mi

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.

NHTSA ID

10230737

Incident

Jun 11, 2008

Mileage

180,000 mi

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 KEEPS THE FRONT OF THE VAN UP OFF OF THE FRONT TIRES. AFTER READING SEVERAL ONLINE FORUMS, IT APPEARS THAT THIS SAME DEFECT HAS CAUSED SEVERAL ACCIDENTS AND NEAR ACCIDENTS TO OTHER ASTRO VAN OWNERS. WHETHER REPORTED OR NOT REPORTED, THE DESIGN OF THE MOUNTING BRACKET FOR THE TORSION BAR WAS MOST LIKELY USED THIS WAY SO THE MANUFACTURED COULD USE ONE SIZE OF TORSION BAR FOR SEVERAL VEHICLES AND THEN MODIFY THE MOUNT ON EACH VEHICLE TO ACCEPT THE SAME SIZE BAR. WE HAVE PURCHASED REPLACEMENT TORSION BARS (GM PARTS) FOR $462.00 AND NEED TO ALSO PAY TO HAVE THEM INSTALLED. THE REPLACEMENT TORSION BARS ARE NOW 3 INCHES SHORTER, PROVING THAT THE MANUFACTURE BECAME AWARE THIS PROBLEM AND CORRECTED IT WITH THE REPLACEMENT PARTS - NOW WITHOUT THE EXTRA 3 INCHES OF OPEN CYLINDER TO COLLECT SALT AND SNOW. I BELIEVE THIS IS A VERY DANGEROUS SITUATION AND THAT THESE PARTS SHOULD BE RECALLED IMMEDIATELY ON ALL VANS WITH THIS SIZE OF TORSION BAR. WE REGULARLY DRIVE THE INTERSTATE AND HAD IT BROKE WHILE WE WERE DRIVING IT, IT WOULD HAVE BEEN LIKE DRIVING ON THE HIGHWAY AND SLAMMING ON YOUR BREAKS (AS THE FRONT OF THE VAN DROPPED DOWN ONTO THE TIRE) AND SUDDENLY LOSING ANY STEERING ABILITY OR WAY TO CONTROL THE VEHICLE. THANKFULLY, WE DIDN'T HAPPEN TO BE DRIVING IT WHEN IT BROKE. *NM

NHTSA ID

10164660

Incident

Jul 21, 2006

Mileage

126,112 mi

AFTER PARKING THE VEHICLE IN THE DRIVEWAY, LATER THE CONSUMER RETURNED TO FIND THE VEHICLE LEFT FRONT LEANING OVER. THE CONSUMER WENT UNDER THE VEHICLE TO SEE WHAT HAPPENED AND IT WAS DISCOVERED, THE TORSION BAR WAS BROKEN. *JB

NHTSA ID

10113534

Incident

Mar 4, 2005

Mileage

140,000 mi

WHILE DRIVING 35 MPH, THE LEFT SIDE OF THE VEHICLE DROPPED TO THE GROUND. THE VEHICLE WAS SERVICED AND THE TECHNICIAN NOTICED THAT THE STABILIZER BAR NEEDED REPLACEMENT. THREE WEEKS AND ONE DAY LATER, THE RIGHT SIDE OF THE VEHICLE DROPPED TO THE GROUND DUE TO THE STABILIZER BAR. THIS OCCURRED WITHOUT WARNING WHILE DRIVING 50 MPH. *JB

NHTSA ID

10073827

WHILE DRIVING AT UNDETERMINED SPEED AND WITH NO WARNING FRONT SUSPENSION COLLAPSED. CONSUMER TOWED VEHICLE TO THE DEALERSHIP. *AK

NHTSA ID

10052061

Incident

Nov 25, 2003

WHILE DRIVING APPROXIMATELY 10-20MPH, THE SUSPENSION TORSION BAR SNAPPED CAUSING VEHICLE'S FRAME TO DROP. TS

NHTSA ID

8021959

Incident

Jul 1, 2002

WHILE DRIVING TORSION BAR FAILED AS A RESULT THE DRIVER WAS UNABLE TO STEER THE VEHICLE, THE DEALER WAS CONTACTED.*AK *NLM

NHTSA ID

8018678

Incident

Sep 16, 2002

VEHICLE WAS PARKED AND CONSUMER GOT OUT OF VEHICLE AND NOTICED LEFT FRONT END OF VEHICLE HAD DROPPED ONTO TIRE. CONSUMER HAD TAKEN VEHICLE TO DEALER WHO STATED THAT TORSION BAR WAS BROKEN. CAUSE UNKNOWN. *AK CONSUMER STATED THAT THE VEHICLE COULD HAVE CAUSED A CRASH DUE TO THE LACK OF CONTROL. ESTIMATED *SCC

NHTSA ID

8012614

Incident

Jun 24, 2002

WHILE LEAVING PARKING LOT AT 5-7 MPH FRONT END OF VAN DROPPED WITHOUT WARNING. MECHANIC STATED FRONT TORSION BAR WAS THE CAUSE OF VEHICLE COLLAPSING.*AK

NHTSA ID

8002846

MECHANIC ADVISES TORSION BAR SHATTERED. COULD HAVE CAUSED FATALITY IF IT HAD HAPPENED AT HIGHWAY SPEED.

NHTSA ID

754132

Incident

Oct 9, 2001

TORSION BAR SHATTERED, COLLAPSING LEFT FRONT OF CAR; COULD HAVE BEEN FATAL ACCIDENT IF IT HAD OCCURRED AT HIGHWAY SPEEDS. *AK

NHTSA ID

753332

Incident

Oct 8, 2001

TORSION BAR FAILURE TOOK PLACE IN THE AREA OF THE BUSHING IN THE TORSION BAR ARM LOCATED IN THE FRAME CROSSMEMBER. THIS WAS A KNOWN DEFECT BY CHEVROLET WHO STATED THEY KNOW OF THIS PROBLEM THRU THE 1998 MODEL YEAR. THE NEW REPALCEMENT PARTS ARE OF A DIFFERENT DESIGN. THE EVENT OCCURED THE MORING AFTER I RETURNED FROM A TRIP THAT WAS PREDONINATELY INTERSTATE DRIVING AND THE COMPONENT FAILED AS I WAS ENTERING THE VEHICLE WHICH WAS PARKED IN MY DRIVEWAY AT THE TIME. HOWEVER HAD I BEEN ON THE INTERSTATE AT THE TIME OF THE FAILURE I'M SURE I WOULD HAVE LOST CONTROL OF THE VEHICLE. WHEN I QUESTIONED THE DEALERSHIP WHERE I HAD THE REPAIRS DONE IF THEY HAD SEEN THIS BEFORE THEY STATED THEY HAD AND "IT WASN'T A PRETTY PICTURE".*AK

NHTSA ID

753017

Incident

Aug 6, 2001

DRIVERS SIDE TORSION BAR BROKE WHILE VAN WAS PARKED IN A PARKING LOT. MY WIFE HAD JUST DRIVEN 50 MILES ON THE NYS THRUWAY AT 65 MPH IN MORNING RUSH HOUR TRAFFIC WITH HER BOSS IN THE VAN GOING TO A NURSING CONFERENCE. THEY PARKED THE VAN IN A PARKING LOT AND WHEN THEY RETURNED 2 HOURS LATER THEY FOUND THE VAN DRIVERS SIDE DOWN ON THE FRONT TIRE. I WOULD HATE TO IMAGIN WHAT COULD HAVE HAPPENED IF THIS HAD HAPPENED IN RUSH HOUR TRAFFIC. WOULD IT HAVE EVEN BEEN RECOGNIZED AS THE CAUSE OF AN ACCIDENT? I HAVE JUST FINISHED READING THE 22 OTHER REPORTED INCIDENTS AND AGREE WITH ALL THE REST THAT THIS IS A MANUFACTURE DEFECT IN EITHER THE BAR OR THE ENGINEERING DESIGN. WHEN THE DEALER REPAIRED THE BROKEN UNIT HE SAID IT WAS SUGGESTED BY GM TO REPLACE BOTH BARS, THE F-SUPPORT "A" AND ARM. WE WERE TOLD THAT THE SUPPORT WAS REQUIRED DUE TO A DESIGN CHANGE, AT A COST TO US OF $859.00 . IT IS VERY APPEARENT TO ME THAT GM HAS RECOGNIZED THE PROBLEM, CHANGED THE DESIGN TO REMEDY THE PROBLEM AND PAST THE COST AND THE VERY POSSIBLE INJURY ON TO THE PUBLIC. THAT I UNDESTAND , WHAT I DON'T UNDERSTAND IS WHY THIS ORGANIZATION, NHTSA, HAS NOT PURSUED GM FOR A RECALL ON THIS ITEM, I AM VERY SUPRISED. THANKS FOR THE SPACE [email protected]. *AK

NHTSA ID

752381

Incident

Sep 5, 2001

WHILE TRAVELING AT APPROXIMATELY 20 TO 25 MPH FRONT LEFT TORSION BAR BROKE. DEALERSHIP HAS EXAMINED VEHICLE, AND WAS REPLACING BOTH FRONTAL TORSION BARS. *AK *SLC

NHTSA ID

893645

Incident

Aug 1, 2001

FRONT LEFT TORSION BAR BROKE WHILE THE VEHICLE WAS PARKED IN GARAGE.*AK

NHTSA ID

893558

Incident

Jul 29, 2001

LEFT FRONT TORSION BAR BROKE WHILE DRIVING 30 MPH. FORTUNATELY THIS DID NOT HAPPEN AT A HIGHER SPEED. DRIVERS SIDE FRONT OF VEHICLE COLLAPSED TO NEARLY TOUCH THE TIRE. HAD THE RIGHT SIDE TORSION BAR REPLACED AS WELL, AT THE RECOMENDATION OF THE SERVICE STATION BECAUSE OF A KNOWN PROBLEM WITH THESE PARTS. WHY WASN'T I NOTIFIED BY CHEVROLET? THIS SEEMS TO BE A POTENTIALLY DANGEROUS CONDITION.*AK

NHTSA ID

749845

Incident

Jul 2, 2001

PASSENGER'S SIDE TORSION BAR SNAPPED IN HALF WHILE BACKING OUT OF A DRIVEW CAR COLLAPSED ON TOP OF TIRES. CONSUMER FELT LUCKY THIS DID NOT HAPPEN ON FREEWAY.*AK

NHTSA ID

888830

Incident

May 19, 2001

ON THE MORNING OF 5/14/99 MY DAUGHTER WENT OUT TO THE GARAGE TO START THE VAN AND SAW THAT THE FRONT OF VAN WAS HANGING OVER THE LEFT FRONT WHEEL AND RUBBING ON THE TIRE. SHE CALLED ME OVER TO SEE WHAT WAS THE PROBLEM. THE LEFT FRONT TORSION BAR SNAPPED AND BROKE CAUSING THE BODY TO FALL OVER THE LEFT FRONT WHEEL, ALSO MY DAUGHTER AT TIME WAS 7 MONTHS PREGNANT, AND VERY CONCERNED ABOUT WHAT WOULD HAPPEN IF SHE HAD BEEN DRIVING WHEN THE TORSION BAR BROKE,CAUSING THE BODY TO FALL OVER THE TIRE,AND SHE WOULDN,T HAVE BEEN ABLE TO STEER THE VAN OUT OF DANGER. I CALLED THE CHEV. GARAGE TO COME PICK UP THE VAN BECAUSE YOU COULDN,T STEER IT. AFTER THEY CONFIRMED WHAT THE PROBLEM WAS,WE ASKED IF THIS WAS SAFETY PROBLEM THEY SAID NO. WE ASKED HOW MANY TORSION BAR HAVE THEY FOUND LIKE THIS, THE SAID NONE, THAN WOULDN,T YOU THINK THAT THEY WOULD LOOK IN TO TORSION BAR AS BEING DEFECTIVE,BUT THEY SAID NEED MORE THAN ONE PROBLEM LIKE THIS TO INVESTIGATE. I CALLED CHEV MOTOR COMPANY AND THE SAID ALMOST THE SAME THING. WELL WE THOUGHT THEY WOULD BE INTERESTED, BUT NO ONE AS CALLED OR SENT ANY INFOMATION, MY DAUGHTER AND HUSBAND HAD TO PAID FO REPAIRS, ALSO WE FOUND OUT THAT NUMBER FOR THE TORSION BAR HAS BEEN CHANGED AND THAT THEY HAD TO REPLACE BOTH BARS WITH NEW DESIGN BRACKETS,WE FOUND THIS TO BE KIND OF SUSPICIOUS. I HOPE THAT THERE WAS NO ONE DRIVING THE SAME TYPE VAN. AND HAD A TORSION BAR BREAK CAUSING A ACCIDENT OR DEATH. THANK YOU FOR LETTING ME GET RID OF SOME MY CONCERNS. THANK YOU AGAIN, ED LANGENBERG 610 RAVENSWOOD DR. GREEN BAY, WI 54302, 920-468-8709, EMAIL [email protected]. *AK

NHTSA ID

741686

Incident

May 14, 1999

TORSION BAR BROKE WHILE DRIVING @ 30MPH ($400), LFT TORSION BAR BROKE IN DRIVEWAY ($364), "CLUNK" IN REAR WHILE ACCELERATING FROM STOP AND OCCASIONALLY WHILE SHIFTING (HIGH/LOW GEAR IN DIFFERENTIAL UNIT-$1500), 9 MOS LATER THE "CLUNK" IS BACK. MECHANICS SAYS DISCONNECT DRIVE TRAIN FROM REAR TO MAKE VAN 2WD

NHTSA ID

731965

Incident

Sep 9, 2000

I DROVE THE AUTO TO WORK, CAME OUT AT BREAK, AND FOUND THE FRONT END CROOKED. SOMETHING HAD BROKEN UP FRONT. UNDER FURTHER CHECKING I SEE THE TORSION BAR, ON THE LEFT SIDE WAS BROKE. I WANTED TO GET AN ESTIMATE OF REPAIR, WHEN I CONTACTED A PLACE IN ERIE, CALLED DIAS SPRING, THEY SAID THEY HAD REPAIRED SEVERAL VEHICLES WITH THE SAME PROBLEM IN A WEEKS TIME. WHAT I WOULD LIKE TO KNOW, IS IT SEEMS THERE IS A MANUFACTURER PROBLEM THAT EXISTS, ON THESE FRONT ENDS. ARE YOU GOING TO UPDATE MY AUTO SO I DON'T HAVE TO PAY THE EXTREME HIGH COSTS OF REPAIR. AUTO SALVAGE YARDS IN OUR AREA CLAIM BIG RUSHES ON GETTING PEOPLE THESE PARTS, IT SEEMS TO ME THERE IS A PROBLEM THAT HAS TO BE ADDRESSED HERE. TOO MANY PEOPLE HAVE HAD THE SAME PROBLEM AS WE. PLEASE CONFIRM MY INQUIRY.( DOT NUMBER: TIRE SIZE: 2251675R15 )

NHTSA ID

730316

Incident

Aug 31, 2000

CONSUMER HEARD A BIG BANG, NEXT DAY VAN WAS LEANING TO THE LEFT, TORSION BAR CRACKED OR FAILED, WHICH INDICATED THAT THERE WAS NO SUSPENSION ON THE LEFT SIDE OF THE VAN. *AK

NHTSA ID

869304

Incident

Aug 25, 2000

VEHICLE EXPERIENCED A FRONT TORSION BAR BROKE, WHILE PULLING OUT OF A DRIVEWAY; DEALER / MFR'S WAS NOT CONTACTED AT THIS TIME. PLEASE PROVIDE ANY FURTHER DETAILS:

NHTSA ID

868807

Incident

Aug 11, 2000

THE TORSION BAR BROKE ON MY VAN LESS THAN 15 MILES AFTER RETURNING FROM A VACATION TO THE MOUNTAINS. MY MECHANIC INFORMS ME THAT THE PARTS ARE BACK ORDERED AND ALMOST IMPOSSIBLE TO LOCATE BECAUSE THIS IS SUCH A COMMON PROBLEM WITH THIS VEHICLE. MY BROTHER WHO WORKS IN THE PARTS DEPARTMENT OF A LARGE AUTOMOBILE DEALERSHIP CONFIRMS THAT THIS HAS BEEN A COMMON PROBLEM. I WANT GM TO STAND BEHIND THE REPAIRS. IF THIS HAD HAPPENED SEVERAL DAYS EARLIER IN THE ROCKY MOUNTAINS I WOULD HAVE HAD A GREAT DEAL OF INCONVIENCE ( BEST CASE SCENARIO) OR MY FAMILY AND MYSELF COULD HAVE BEEN PLACED IN DANGER BECAUSE OF LOSING CONTROL OF THE VEHICLE ON A MOUNTAIN ROAD (WORSE CASE SCENARIO). IF THIS IS A COMMON PROBLEM, GM NEEDS TO STAND BEHIND IT! *AK

NHTSA ID

727517

Incident

Aug 5, 2000

THE VEHICLE WAS BACKING UP WHEN THE LEFT FRONT TORSION BAR FRACTURED. THE BODY CAME DOWN ON THE LOWER 'A' FRAME STOP. THE TURNING RADIUS WAS REDUCED TO CREATE SOME MAJOR CONCERN. I HAVE TALK WITH GM AND NO RECALL CAMPAIGN IS CURRENTLY ACTIVE FOR THIS VEHICLE. BUT, GM HAS DONE A REDESIGN ON THE TORSION BAR ASSEMBLIES. THEY RECOMMEND REPLACEMENT OF BOTH TORSION BARS AND ADJUSTERS TO A NEW DESIGN THEY HAVE SHORTENED THE TORSION BAR TO GIVE IT LESS TWIST. MY CONCERN IS THE DRIVABILITY OF THE VEHICLE UPON LOSE OF SUSPENSION. PLEASE LET ME KNOW IF OTHERS ARE HAVING THE SAME COMPLAINT.*AK

NHTSA ID

725617

Incident

Jul 13, 2000