1996 Chevrolet Astro Suspension Problems

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

NHTSA ID

10329317

Incident

Apr 26, 2010

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

NHTSA ID

10122345

Incident

May 25, 2005

Mileage

71,000 mi

PART#15990701 FAILED,BROKE.CAUSING LEFT CORNER OF VECHICLETO DROOP ALMOST TO INTERFERING WITH LEFT FRONT WHEEL.THIS PART IS COMMINLY KNOWN AS A TORSION BAR AND SHOULD NOT BE FAILING/.THERE WAS NO ACCIDENT.THIS VECH.IS IN EXCELLENT CONDITION AND HAS NEVER BEEN ABUSED.REPARING THIS IS GOING TO BE COSTLY;OVER 1000.00 DOLLARS.BECAUSE THEIR ARE NO ORIGINAL PARTS.THE PARTS HAVE BEEN UPDATED AND ALL NEW PARTS FOR BOTH SIDES OF THE VECH. MUST BE USED.THIS TELLS ME THEIR WAS BAD ENGINEERING IN THE ORIGINAL DESIGN. NOW THAT THEY'VE FIXED THE PROBLEM THEY WANT THE CUSTOMER TO PAY THE BILL. THANK YOU. RESPECTFULLY RICHARD WAGNER. *AK

NHTSA ID

10086319

Incident

Aug 4, 2004

Mileage

80,222 mi

I WOULD LIKE TO REPORT WHAT I FEEL IS/WAS A VERY SERIOUS SAFETY DEFECT WITH MY 1996 CHEVROLET ALL WHEEL DRIVE ASTRO VAN [XXX]. RECENTLY WHILE DRIVING THE RIGHT FRONT SUSPENSION TORSION BAR SNAPPED, COLLAPSING THE SUSPENSION, DROPPING THE ENTIRE RIGHT SIDE ON TOP OF THE RIGHT FRONT WHEEL AND TIRE PULLING DRASTICALLY TO THE RIGHT ACROSS 2 LANES OF TRAFFIC. FORTUNATELY TRAFFIC WAS LIGHT, AND I WAS TRAVELING AT A SLOW SPEED -ABOUT 40 KM/HR IN A POSTED 50KM ZONE AS I HAD JUST ENTERED THE 4-LANE ROADWAY. I MANAGED TO REGAIN CONTROL OF THE VAN AND STEER IT TO THE SIDE OF THE RIGHT HAND SIDE OF THE ROAD. I SHUDDER AT THE THOUGHT IF THIS HAD HAPPENED ON THE HIGHWAY OR FREEWAY. THE LICENSED JOURNEYMAN MECHANIC THAT LOOKED AT THE VAN INDICATED THIS WAS QUITE COMMON ON 90-96 ALL WHEEL DRIVE VANS STATING THAT THE TORSION BAR ACTUALLY RUSTS OR CORRODES AT ALMOST THE EXACT SAME SPOT (NEAR THE ADJUSTER ASSEMBLY) AND EVENTUALLY SNAPS COMPLETELY BREAKING THE TORSION BAR INTO 2 PIECES! WHILE HE MENTIONED IT WAS USUALLY THE DRIVER'S SIDE (MINE WAS PASSENGER SIDE) HE INDICATED GM HAD RECOGNIZED THE PROBLEM AND ACTUALLY COMPLETELY CHANGED THE DESIGN OF BOTH THE TORSION BAR AND THE ADJUSTER MECHANISM! HOWEVER AFTER CONTACTING A COUPLE OF LOCAL GM DEALERS, THEY ALL TOLD ME WAS THAT THIS WAS NOT A PRODUCT SERVICE BULLETIN RELATED ITEM OR AN OFFICIAL SAFETY RECALL! YET THEY ALL HAD HEARD OF IT AND JUST HAPPENED TO HAVE ALL OF THE PARTS IN STOCK TO THE TUNE OF $1000 (YOU HAVE TO REPLACE BOTH SIDES WITH THE REDESIGNED ITEMS). I FOUND IT SURPRISING THAT THEY JUST HAPPENED TO HAVE 6 TORSION BARS AND 6 ADJUSTERS IN-STOCK; WHEN I RECENTLY HAD TO SPECIAL ORDER THE REAR DOOR HANDLE THAT HAD BROKEN. I WAS TOLD THEY ONLY STOCK COMMONLY REPLACED ITEMS AT THAT TIME. THE FACT THAT IT WAS REDESIGNED TELLS ME SOMETHING. A COMPONENT THAT IS SUBJECT TO WEAR SHOULD HAVE SOME SORT OF PUBLISHED INSPECTION PROCESS, WEAR MEASUREMENT PROCEDURE OR EVEN A REGULARLY SCHEDULED REPLACEMENT INTERVAL. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATI

NHTSA ID

10071346

Incident

Jun 15, 2003

No narrative was included with this report.

NHTSA ID

10069428

Incident

Jul 15, 2003

Mileage

65,000 mi

TORSION BAR BROKE, DEALER CLAIMS THAT IT WAS A DEFECT IN THE DESIGN OF THE TORSION BAR, THE BAR WAS TO LONG. NOW THEY HAVE A SHORTER BAR. I HAD TO REPLACE BOTH SIDES WITH THE NEW DESIGN BECAUSE THE ORIGINAL PART WAS DISCONTINUED.

NHTSA ID

10069243

Incident

Aug 15, 2003

Mileage

92,000 mi

MY WIFE WENT TO MOVE OUR 1996 CHEVROLET ASTRO VAN AND WHEN SHE BACKED UP THE RIGHT FRONT TIRE WAS RUBBING ON THE WHEEL WELL. UPON FURTHER INVESTIGATION IT WAS DETERMINED THAT ONE OF THE TORSION BARS BROKE. *AK WHEN I CALLED MY LOCAL DEALER I FOUND THE PARTS WERE READILY AVAILABLE BUT I WOULD HAVE TO REPLACE BOTH SIDES BECAUSE THEY HAD BEEN "UPDATED". THE PARTS ALONE WERE OVER $500.00. WHEN I REMOVED THE OLD TORSION BARS I FOUND OUT WHAT HAD CAUSED IT TO BREAK, THE RECEIVER TUBE THAT THE END OF THE BAR WENT INTO HAD FILLED WITH DIRT AND ROAD CRUDE CAUSING THE BAR TO RUST AND EVENTULLY BREAK. THIS OCCURED FOUR DAYS BEFORE WE WERE LEAVING ON A 2500 MILE TRIP. IF THIS HAD OCCURED WHEN WE WERE GOING DOWN THE INTERSTATE AT 75MPH OR IN THE MOUNTAINS WHILE ON VACATION IT COULD HAVE BEEN DIASATEROUS. MY LAST COMPLAINT IS THAT I WAS REQUIRED TO REPLACE BOTH TORSION BARS BECAUSE THE NEW ONE WOULD NOT MATCH THE OLD. YOU SHOULD NOT HAVE TO REPLACE SOMETHING THAT IS NOT BROKEN AND IF THEY DO REQUIRE YOU TO DO SO THE MANUFACTURER IS ADMITTING THERE IS A PROBLEM WITH THE OLD DESIGN. I CHECKED IN YOUR RECORDS AND FOUND THAT THE ASTRO AND SAFARI VANS BUILT FROM 1992-1996 HAD ALMOST 200 CASES OF THESE TORSION BARS BREAKING AND A COMPLAINT BEING FILED. WHO KNOWS HOW MANY OTHER ONES HAVE BROKEN AND GONE UNREPORTED.THE 1997 MODELS DID NOT SEEM TO HAVE A PROBLEM BECAUSE THEY CAME OUT WITH THE UPDATED PARTS.

NHTSA ID

10046024

Incident

Jul 29, 2002

Mileage

83,000 mi

FRACTURE OF RIGHT SIDE TORSION BAR CAUSED BODY TO DROP ONTO WHEEL, IMMOBILIZING VEHICLE. REPAIRS COST $797.12 PLUS $40 TOWING AND LOSS OF USE FOR THREE DAYS.*AK

NHTSA ID

10033453

Incident

Aug 19, 2003

Mileage

127,261 mi

DRIVER'S SIDE TORSION BAR BROKE. I'VE SEEN NUMEROUS COMPLAINTS OF THIS SAME FAILURE ON VARIOUS WEB SITES. FORTUNATELY, MY TORSION BAR BROKE WHILE BACKING OUT OF OUR DRIVEWAY. THIS COULD HAVE BEEN A CATASTROPHIC FAILURE HAD IT OCCURED WHILE DRIVING ON THE FREEWAY.

NHTSA ID

10030630

Incident

Aug 2, 2003

WHILE DRIVING, THE TORSION BAR BROKE (WHICH WAS THE SECOND TIME THE INCIDENT HAPPENED) DEALER AND MANUFACTURER WERE NOTIFIED. *JB

NHTSA ID

10019685

Incident

May 12, 2003

THE TORSION BAR SNAPPED WITHOUT WARNING. JB

NHTSA ID

10015996

Incident

Apr 12, 2003

THE CONSUMER SAT IN THE DRIVEWAY, THE LEFT SIDE TORSION BAR SNAPPED. THE FRONT LEFT SIDE OF THE VEHICLE WAS SITTING ON THE LEFT FRONT TIRE. THE PART WAS ONLY AVAILABLE THROUGH THE DEALER. BY COINCIDENCE THE RIGHT SIDE WAS SENT AS WELL AND WAS SOLD BY THE PAIR. THE PARTS WERE REDESIGNED AND A NEW BUT DIFFERENT BRACKET WAS INCLUDED. GM FORCED THE REPAIR OF BOTH SIDES AT THE EXPENSE OF THE CONSUMER. *JB *SCC

NHTSA ID

10015592

Incident

Apr 4, 2003

Mileage

95,690 mi

VEHICLE WAS BACKING OUT OF DRIVEWAY, WHEN A LOUD NOISE PROCEEDED THE FRONT DRIVER SIDE OF THE VAN COLLAPSING ONTO THE FRONT TIRE. THE CHEVROLET DEALER INFORMED ME THAT THE TORSION BAR HAD FAILED, AND AS THE PART HAD BEEN REDESIGNED, THE PASSENGER SIDE WOULD ALSO BE REPLACED. I REQUESTED THE PARTS BE RETURNED, AND AFTER VISUALLY INSPECTING, IT IS VERY APPARENT THAT THE PART FAILED DUE TO SEVERE RUST AND CORROSION. THE ORIGINAL INSTALLATION OF THE TORSION BAR HAS A RETAINING SLEEVE THAT FITS OVER THE FAILED END OF THE TORSION BAR, AND CONNECTS INTO THE CROSSMEMBER. THE SLEEVE IS DESIGNED IN SUCH A WAY THAT IT COLLECTS MOISTURE. THIS IN TURN CAUSES APPROXIMATELY 6 INCHES OF THE TORSION BAR TO CORRODE, DEGRADING THE INTEGRITY OF THE UNIT. WITH OVER 25 YEARS OF EXPERIENCE AS A MECHANIC IN THE AVIATION FIELD, I AM VERY FAMILIAR WITH CORROSION AND METAL FATIQUE. THE NEW DESIGN OF THE REPLACEMENT PARTS, ELIMINATES THE SLEEVE ENTIRELY, AND THERE IS NO MOISTURE COLLECTION POINTS. CHEVROLET IS AWARE THERE IS A PROBLEM, BUT AS LONG AS THE CONSUMER IS PAYING THE BILL, WHY PUBLICLY ADMIT IT? WITH THE REPAIR COST AND AGGRAVATION SET ASIDE, THE REAL ISSUE RELATED TO THIS FAILURE IS SAFETY. MY FAMILY HAD BEEN ON THE HIGHWAY JUST A FEW MINUTES BEFORE THE TORSION BAR FAILED. WHEN THE FRONT END COLLAPSES, THE STEERING CAPABILITY OF THE VEHICLE IS CLOSE TO NON EXISTANT. THIS IS A SAFETY ISSUE!!! THE SAFETY ASPECT AFFECTS THE PASSENGERS IN THE VEHICLE, OTHER MOTORISTS, AND PEDESTRIANS. I ALSO NOTICED FROM THE NUMEROUS COMPLAINTS ON THIS WEB SITE, THAT SEVERAL OF THE FAILURES OCCURRED WHILE THE VEHICLE WAS PARKED. THIS IS EVEN A SAFETY ISSUE TO ANYONE AROUND THE VEHICLE, INCLUDING CHILDREN AND MECHANICS WHO MIGHT BE NEAR OR UNDER THE VEHICLE WHEN THE FAILURES OCCUR. IN MY OPINION, CHEVROLET HAS NO INTENTION OF INITIATING A RECALL ON THEIR OWN. UNFORTUNATELY, WITH THE NUMBER OF FAILURES OCCURING ON VEHICLES THAT ARE ONLY A FEW YEARS OLD, THE MAJORITY OF FAILURES ARE YET TO COME. *JB

NHTSA ID

10008103

Incident

Jan 28, 2003

THE OWNER MADE AN ATTEMPT TO STEP INTO THE VAN WHEN THE TORSION BAR SNAPPED. THIS CAUSED THE VAN TO COLLAPSE IN THE FRONT, TO THE GROUND WITH NO WARNING. NLM *SCC

NHTSA ID

8019777

Incident

Sep 27, 2002

CONSUMER WAS IN THE GARAGE, WHEN THERE WAS A LOUD NOISE. THE LEFT FRONT END HAD COLLASPED. THE VEHICLE WAS TOWED TO A LOCAL GARAGE, AND THEY SAID THAT THE TORSION HAD BROKEN.*SCC

NHTSA ID

567346

WHILE DRIVING THE CONSUMER HEARD A POPPING NOISE. WHEN THE VEHICLE WAS PULLED OVER, AND THE FRONT END DROPPED A FEW INCHES. DEALER DETERMINED THAT TORSION BAR HAD BROKEN. *AK THE CONSUMER STATED THAT THIS WASN'T THE FIRST TIME THIS PROBLEM HAPPENED, IN RE: 1988 ASTRO VAN. SCC

NHTSA ID

8017875

Incident

Jul 20, 2002

Mileage

78,000 mi

WHILE DRIVING 25-30 MPH DRIVER'S FRONT SIDE OF VEHICLE DROPPED ONTO WHEEL WELL VEHICLE WAS TOWED TO DEALER, FRONT TORSION BAR HAD BROKEN.*AK

NHTSA ID

8016694

Incident

Aug 15, 2002

CONSUMER STATES AFTER THE TORSON BAR FAILED, THE FRONT TIRE RUBBED AGAINST FRAME OF VEHICLE.*AK *JB

NHTSA ID

8015169

Incident

Jul 5, 2002

WHILE DRIVING AT 65MPH ON THE HIGHWAY AND GOING OVER AN OVERPASS 2 TORISON BARS BROKE CAUSING THE FRONT END TO FALL WHICH ALMOST RESULTED IN AN ACCIDENT. *AK *SCC

NHTSA ID

8015157

Incident

Jul 20, 2002

WHILE THE VEHICLE WAS PARKED THE RIGHT AND LEFT SIDE TORSION BARS BROKE WITHIN THE RETAINER AND CAUSED THE VEHICLE TO DROP. DEALER HAS BEEN NOTIFIED AT THIS TIME. *AK *YH

NHTSA ID

8014376

Incident

Jul 5, 2002

THE LEFT TORSION BAR ON THE FRONT SUSPENSION FAILED WHILE THE VAN WAS SITTING IN THE DRIVEWAY. CHAMPION CHEVROLET IN HOWELL, MI SAID THIS IS COMMON. THEY ALSO INTSRUCTED ME TO REPLACE THE RIGHT TORSION BAR BECAUSE IT COULD FAIL AT ANY TIME. MY COMPLAINT IS CHEVROLET IS SUGGESTING (WHICH I DID) REPLACE AN ORIGINAL PART THAT IS NOT BROKEN. GM HAD AN UPDATED PART# BECAUSE THEY NEW THIS IS A COMMON FAILURE. I THINK IF A DEALER IS SUGGESTING YOU REPLACE A PART THAT IS NOT BROKEN AND SAYS IT IS FOR YOUR SAFETY, THEN THAT SHOULD BE A WARRANTY ITEM REPLACEMENT.*AK

NHTSA ID

762987

Incident

Jun 8, 1999

WHILE VEHICLE WAS PARKED AND HAD GOTTEN OUT OF THE FRONT END AND FELL TO THE GROUND DUE TO THE TORSION BAR BREAKING. DEALER CONTACTED. *AK *SCC

NHTSA ID

8010454

Incident

May 23, 2002

FRONT TORSION BAR SNAPPED WHILE CONSUMER WAS PULLING OUT OF PARKING LOT. CONTACTED DEALER. *AK *MJ

NHTSA ID

8008572

Incident

Apr 21, 2002

LEFT FRONT TORSION BAR FAILED AND VEHICLE'S FRONT END DROPPED APPROXIMATELY 6 INCHES. I WAS TOLD THAT THERE WAS A DESIGN CHANGE THAT REQUIRED BOTH LEFT AND FRONT TORSION BARS TO BE REPLACED. ADDITIONALLY, WHEN THE VAN COLLAPSED, AN ENGINE OIL LINE WAS DAMAGED. TOTAL COST: $891.47. DESIGN CHANGE INDICATES THAT ENGINEERING WAS AWARE OF THE PROBLEM AND DESIGNED A MORE ROBUST TORSION BAR. THIS IS A CRITICAL SAFETY ISSUE, AND YET I WAS TOLD THAT THE VEHICLE IS OUT OF WARRANTY. IT IS NOT REASONABLE TO EXPECT THIS TYPE OF FAILURE, NO MATTER HOW OLD THE VEHICLE. ONE WOULD NOT REASONABLY EXPECT THE FRAME OF A 10 YEAR OLD VEHICLE TO COLLAPSE. LIKEWISE, ONE WOULD NOT EXPECT FAILURE OF TORSION BARS THAT SUPPORT THE VEHICLE. I WAS LUCKY THAT THE VEHICLE WAS PARKED WHEN THE INCIDENT HAPPENED. IF MOVING, TOTAL LOSS OF CONTROL WOULD HAVE BEEN THE RESULT.*AK

NHTSA ID

758780

Incident

Nov 14, 2001

TORSION BAR BROKE AND FRONT SUSPENSION DROPPED ABOUT 5 INCHES WHILE DRIVING VEHICLE. CONTACTED DEALER, AND DEALER STATED THERE WAS NO RECALL. DEALER TOLD CONSUMER TO CALL NHTSA.*AK

NHTSA ID

897314

Incident

Oct 2, 2001