2002 Chevrolet Astro Brakes Problems

I GOT IN MY VAN TO DRIVE TO A STORE AND THE BRAKE PEDAL WENT RIGHT TO THE FLOOR. THERE WAS BRAKE FLUID LEAKING FROM NEAR THE REAR TIRE. THE STEEL HARD BRAKE LINE RUNNING FROM THE ABS UNIT TO THE REAR AXLE IS RUSTED THROUGH AND IS LEAKING. THIS WAS A SUDDEN EVENT. ALSO THE FUEL LINES LOOK TO BE JUST AS BAD. I'M SURE STAINLESS STEEL LINES WOULD NOT HAVE ADDED MUCH TO THE VEHICLES COST AND WOULD HAVE PREVENTED THIS HAZARD AND EXPENSE. *TR

NHTSA ID

10706501

Incident

Apr 19, 2015

Mileage

113,000 mi

VEHICLE LOST ALL ELECTRICAL POWER TO EVERY SYSTEM THAT IS CONTROLLED BY THE IGNITION BEING TURNED ON. DRIVER WAS IN THE PROCESS OF MAKING A U-TURN AROUND A CURBING ISLAND IN THE DIVIDED TRAFFIC ROAD WHEN ALL ELECTRICAL WAS INTERRUPTED WHILE THE STEERING WHEEL WAS TURNED ALL THE WAY TO THE LEFT. CONDITION CAUSED STEERING TO BECOME DIFFICULT, BRAKE PEDAL WENT CLEAR TO THE FLOOR, AIR CONDITIONING AND RADIO AND HEADLIGHTS ALL WENT OFF. CONDITION WAS REPEATABLE WITH EXCEPTION OF BRAKE PEDAL, EACH TIME STEERING WAS TURNED TO THE LEFT. INSPECTION UNDER VEHICLE FOUND THAT MAIN POWER CABLE IS ROUTED ACROSS FRONT SIDE OF MAIN FRAME MOTOR MOUNT MEMBER. THERE WAS A SLIGHT CURVE IN THE WAY THE WIRE WAS ROUTED AND EACH TIME THE STEERING WAS TURNED TO THE LEFT, THE INNER TIE ROD END FOR THE RIGHT WHEEL CAME IN CONTACT WITH THE WIRE HARNESS. AFTER MANY MILES, THE PROTECTIVE COVER AND THEN THE ACTUAL WIRE INSULATION WAS RUBBED THROUGH. THIS CAUSED A DIRECT SHORT TO GROUND THROUGH THE STEERING PARTS OF ALL (SWITCHED WHILE RUNNING) ELECTRICAL COMPONENTS OF THE VEHICLE. PROBLEM WAS CORRECTED BY TAPING THE WIRE INSULATION, THEN TAPING THE PROTECTIVE COVERING. I THEN HAD TO FABRICATE A BRACKET TO SCREW TO THE STEEL CRUMPLE MEMBER TO HOLD THE HARNESS BACK FROM THE STEERING LINKAGE. *TR

NHTSA ID

10546973

Incident

Aug 14, 2013

Mileage

120,000 mi

ABS WAS ACTIVATED AT SLOW SPEEDS CAUSING A SUBSTANTIAL DROP IN BRAKING POWER. *TR

NHTSA ID

10468081

Incident

Jul 28, 2012

Mileage

79,000 mi

ABS COMING ON AT VERY LOW SPEEDS ON DRY PAVEMENT (UNDER 5MPH/8KMH). IT DOESN'T DO IT EVERY TIME, BUT QUITE OFTEN AT LOW SPEEDS, LIKE COMING TO A RED LIGHT, STOP SIGN OR PARKING. OF COURSE, THERE IS NO NEED FOR THE ABS COME ON AT SUCH LOW SPEEDS AND ESPECIALLY NOT ON DRY PAVEMENT. *TR

NHTSA ID

10432683

Incident

Oct 13, 2011

Mileage

106,872 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET ASTRO. THE CONTACT STATED THAT THE FRONT BRAKE LINES WERE RUSTED. THE ABS UNIT WAS NOT WORKING PROPERLY AND THE REAR BRAKES HAD ALREADY FAILED. THE VEHICLE WAS NOT INSPECTED BY THE DEALER BUT WAS REPAIRED BY THE CONTACT. THE CURRENT MILEAGE WAS 79,000 AND THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10432394

Incident

Oct 13, 2011

TL* THE CONTACT OWNS A 2002 CHEVROLET ASTRO VAN. WHEN DRIVING AT LOW SPEEDS THE ANTI-LOCK BRAKING SYSTEM WOULD ACTIVATE WITHOUT WARNING, INCREASING THE VEHICLE'S STOPPING DISTANCE. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 76,000. UPDATED 5/12/10 *CN UPDATED 06/18/10.*JB

NHTSA ID

10319196

Incident

Feb 1, 2010

Mileage

76,000 mi

TL*THE CONTACT OWNS A 2002 CHEVROLET ASTRO VAN. THE CONTACT STATED THAT WHILE DRIVING IN RESERVE AT APPROXIMATELY 5 MPH, THE BRAKES AND THE POWER STEERING MALFUNCTIONED. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC. THE MECHANIC COULD NOT REMEDY THE PROBLEM. THE CONTACT STATED THAT THE VEHICLE WAS UNSAFE TO DRIVE. THE FAILURE MILEAGE WAS 25,000.

NHTSA ID

10315519

Incident

Jan 10, 2009

Mileage

25,000 mi

TL. CONTACT OWNS A 2002 CHEVY ASTRO VAN. CURRENT MILEAGE WAS 97,000 AND FAILURE MILEAGE WERE 50,000. CONTACT STATED UPON PURCHASING THE VEHICLE FROM ENTERPRISE CAR RENTAL THE BRAKES HAVE BEEN BAD. CONTACT STATED THAT THE VEHICLE HAS BEEN IN THE SHOP OVER 20 TIME MOST OF THE TIME FOR THE BRAKES. CONTACT HAS CRASH THE DUE TO THE BRAKES ON THE VEHICLE. CONTACT FEELS THATTHE VEHICLE WAS A LEMON UPON PURCHASE AND DOES NOT FEEL THIS VEHICLE SHOULD BE ON THE ROAD. JO

NHTSA ID

10259849

Incident

May 22, 2005

Mileage

50,000 mi

ON MARCH 26, 2008, I TOOK MY 2002 CHEVY ASTRO VAN TO BE SERVICED. MILEAGE 93,829,I HAD NO BRAKES. THE MASTER CYLINDER WAS DETERMINED TO BE THE CAUSE OF THE FAILURE AND WAS REPLACED. ON APRIL 12, 2008, ONCE AGAIN I HAD NO BRAKES, THIS TIME IT RESULTED IN ME GETTING INTO AND ACCIDENT. I TOOK THE VAN BACK TO THE SAME REPAIR SHOP. WHEN THEY PUT IT ON THE LIFT THEY SAID THE WHOLE BRAKING SYSTEM WAS MELTED UNTIL THE POINT OF THE HOSE BURSTING. HE SAID HE NEVER SAW ANYTHING LIKE THIS IN HIS 20 YEARS OF SERVICE. THEY DID NOT WANT TO TOUCH IT STATING IT WAS NOW A LIABILITY TO THEM AND DIRECTED ME TO CHEVY. CHEVY CONCURRED, FOUR DIFFERENT PEOPLE SAID THEY HAVE NEVER SEEN OR HAVE A CLUE AT WHAT CAUSED THIS. THEY CALLED IN GM, WHO ALSO NEVER HAD SEEN THIS, BUT BOUNCED THE BLAME ON A QUESTIONABLY INSTALLED MASTER CYLINDER. CHEVY SAID THEY CAN REPLACE THE WHOLE BRAKING SYSTEM BECAUSE THEY DO NOT KNOW WHAT IS WRONG, BUT SINCE THEY DO NOT KNOW WHAT CAUSED THIS OR WHY FUSES DIDN'T BLOW TO PREVENT IT, IT COULD HAPPEN AGAIN. WE HIRED OUR OWN CAR CONSULTANT TO LOOK AT THE VAN, HE TOO HAS NEVER SEEN OR HEARD OF ANYTHING LIKE THIS. THE HEAT AND MELTED BRAKE LINES RAN CLOSER THAN 1/4 INCH AWAY FROM THE GAS TANK. I DO NOT WANT TO TAKE THE RISK OF DRIVING AGAIN WITH MY CHILDREN AND LOOSING BRAKES OR POSSIBLY IGNITING THE GAS TANK. *TR

NHTSA ID

10248363

Incident

Apr 12, 2006

Mileage

94,339 mi

TL*THE CONTACT OWNS A 2002 CHEVROLET ASTRO. WHILE THE VEHICLE WAS UNDERGOING A ROUTINE INSPECTION, THE CONTACT WAS INFORMED THAT HIS EXTERIOR LIGHTING/BRAKE LIGHT SWITCHES WERE INOPERATIVE. HE CALLED THE DEALER IN REFERENCE TO NHTSA CAMPAIGN ID NUMBER 05V099000 (EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH). THE DEALER STATED THAT HIS VIN WAS NOT INCLUDED IN THE RECALL ALTHOUGH THE FAILURES WERE IDENTICAL. THE CONTACT WOULD BE RESPONSIBLE FOR THE REPAIR COSTS. THE MANUFACTURER DID NOT PROVIDE ANY ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE 70,000.

NHTSA ID

10231300

Incident

Jun 5, 2008

Mileage

70,000 mi

OPERATED THE VAN FOR 30 MINUTES. PARKED IT IN A GARAGE AND SHUTOFF ENGINE. TEN MINUTES LATER THE GARAGE SMOKE ALARM SOUNDED. THE VAN HAD FILLED THE GARAGE FULL OF SMOKE. OPENED THE DOOR AND ATTEMPTED TO RESTART THE ENGINE TO REMOVE FROM GARAGE. DISPLAY REPORTED AN ASSORTMENT OF WARNINGS AND ENGINE STARTER FAILED TO ACTIVATE. OPENED HOOD TO DISCOVER FLAMES COMING FROM THE UNDERSIDE ON THE ENGINE. CALLED FOR FIRE DEPARTMENT AND MADE FIRST ATTEMPT TO USE A FIRE EXTINGUISHER TO STOP FLAMES FROM THE ENGINE COMPARTMENT, WAS UNSUCCESSFUL. WENT UNDER THE VAN'S DRIVER-SIDE AND COULD NOW SEE THE SOURCE OF FIRE. EXTINGUISHED THE FIRE, THEN IT SHORTLY ERUPTED AGAIN. EXTINGUISHED AGAIN. PLACED THE KEY INTO THE STEERING COLUMN TO MOVE TRANSMISSION TO NEUTRAL, SO THAT I COULD PUSH THE VEHICLE OUT OF THE GARAGE. SPARKS IMMEDIATELY FLEW FROM THE DRIVER-SIDE UNDERSIDE AND RE-IGNITED THE FIRE. THE TRANSMISSION LEVER WAS NO LONGER ENGAGED TO THE TRANSMISSION (CONTROL WAS LIMP) AND THE KEY SEIZED IN THE COLUMN. WENT UNDERNEATH THE VEHICLE TO EXTINGUISH THE FIRE A THIRD TIME. AFTER THIS I REMOVED THE POSITIVE POWER LEAD FROM THE BATTERY TO STOP ANY FURTHER ELECTRICAL SHORTS. FIRE SUBSIDED. FIRE DEPARTMENT ARRIVED AND ORDERED A WRECKER TO DRAG THE VEHICLE FROM THE GARAGE FOR SAFETY OF THE HOUSE. AT THIS TIME IT WAS DISCOVERED THAT THE FIRE HAD ALSO DESTROYED THE EMERGENCY BRAKE SYSTEM. THE PARKING BRAKE WAS SEIZED IN THE OFF POSITION. CHEVROLET DEALERSHIP REPAIR ORDER STATES AS FOLLOWS: "APPEARS EBCM SHORTED AND CAUGHT FIRE BURNING A HOLE THROUGH THE BRAKE LINE. PARKING BRAKE CABLE. SHIFTER CABLE AND WIRING HARNESS." THE EBCM FIRE NOT ONLY CAUSED THE LOSS OF NORMAL BRAKING OPERATION, THE POOR LOCATION OF UNIT AND SUBSEQUENT FIRE IT STARTED DESTROYED THE EMERGENCY BRAKING SYSTEM AND SEVERED THE CONTROLS TO THE TRANSMISSION. THIS LEAVES A DRIVER WITH A COMPLETE LOSS OF BRAKING FUNCTIONS AND NO MEANS TO SLOW THE VEHICLE THROUGH DOWN SHIFTING THE TRANSMISSION. $6000 OF DAMAGE. *JB

NHTSA ID

10204029

Incident

Aug 13, 2007

Mileage

123,000 mi

DT*: THE CONTACT STATED WHILE APPLYING BRAKE PRESSURE AT VARIOUS LOW SPEEDS, THERE WAS AN INCREASED STOPPING DISTANCE, AND THE ANTILOCK BRAKES ACTIVATED WITHOUT WARNING. THERE WAS A NHTSA RECALL, # 05V379000, REGARDING THE ANTILOCK BRAKES. THE VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO THE VIN. THE DEALER AND MANUFACTURER WERE ALERTED. UPDATED 12/15/2006 - THE DEALER TOLD THE CONSUMER THAT THE ASTRO WAS BUILD ON THE SAME FRAME AS THE SILVERADO WHICH WAS BEING RECALLED. *NM

NHTSA ID

10174722

Incident

Nov 29, 2006

Mileage

69,200 mi

I BEGAN HAVING A SITUATION WHERE MY ANTI-LOCK BRAKE SYSTEM WOULD ACTIVATE AT SLOW SPEEDS <10 MPH SUCH AS WHEN PULLING INTO A PARKING SPACE - THIS RESULTS IN THE VEHICLE GOING FORWARD FARTHER THAN IT NORMALLY WOULD - PLEASE NOTE THAT I DID NOT HAVE ANY ACCIDENTS. I TOOK IT TO THE DEALER WHICH INDICATED THAT IT WAS A COMMON PROBLEM AND THEY MAY BE ABLE TO CLEAN THE SENSORS OF CORROSION (THEY DID NOTE THAT THE SENSORS ARE LIGHTLY BUILT AND COULD BREAK REQUIRING REPLACEMENT DURING THE CLEANING PROCESS - WHICH THEY DID). I VOICED MY CONCERN TO GM VIA THERE CUSTOMER SERVICE SYSTEM THAT THIS FAILURE OCCURRED AT 42000 MILES ON A SAFETY RELATED SYSTEM (3 YEARS FROM IN SERVICE DATE - 6000 MILES OUT OF WARRANT). I CLEARLY INDICATED THAT I FELT THIS WAS A FLAW ON WHAT I CONSIDER TO BE A CRITICAL COMPONENT. AS OF THIS POINT - 1 WEEK LATER - GM'S ONLY RESPONSE WAS THAT MY CONCERN WOULD BE MADE KNOWN TO THE MANAGEMENT OF THE COMPANY. NO ACTION TO INFORM ME OF THE RECALL THAT I HAVE RECENTLY READ ABOUT WAS MADE, NOR WAS ANY ACTION TO COVER THE APPROXIMATELY $500 BILL. NOTE THAT THE RECALL THAT HAS BEEN IN THE NEWS DID NOT MENTION CHEVY ASTROS WHICH MY VEHICLE IS - HOWEVER THE PROBLEM SOUNDS IDENTICAL AND MY VEHICLE IS A TRUCK BASED GM VEHICLE WITH ALL WHEEL DRIVE AND ANTILOCK BRAKES - SIMILIAR TO ALL THE MODELS MENTIONED IN THE RECALL. *NM

NHTSA ID

10135013

Incident

Aug 26, 2005

Mileage

42,000 mi

THE CONSUMER'S ANTI-LOCK BRAKES DON'T WORK PROPERLY WHEN PULLING INTO A PARKING SPACE OR UNDER 10 MPH. THE CONSUMER HAD TO PUMP THE BRAKES IN ORDER TO GET VEHICLE TO STOP OR FOR WARNING BEFORE SLOWING DOWN. THE VEHICLE HAS ALL WHEEL DRIVE. THE CONSUMER PULLED FUSE FOR ANTI-LOCK BRAKE MANY TIMES, AND IT WORKED FINE WITHOUT THE FUSE. *AK *SB PULLING THE ANTI-LOCK BRAKE FUSE DEACTIVATED THE ANTI-LOCK BRAKES CAPABILITY. WITH THE ANTI-LOCK BRAKE FUSE IN, THE CONSUMER NEARLY RUNS INTO THE BACK OF VEHICLES WHEN STOPPING. THE CONSUMER STATED THAT THE INCIDENTS HAPPENS ONLY WHEN THE FUSE IS IN AND OCCURED THREE TIMES AT LOW SPEED FOR NO REASON.*SB *NM

NHTSA ID

10119735

Incident

Oct 15, 2004

Mileage

40,000 mi

DT: SHIFT INDICATOR WAS INDICATING THE WRONG GEAR. WHILE DRIVING THE ROAD THE INDICATOR WAS MOVING, BUT THE SHIFTER ITSELF. EVERY TIME I DROVE THE VEHICLE THIS HAPPENED. IT WAS TAKEN TO DEALER TO FIX AND STATED THERE WERE A LOT OF COMPLAINT. THIS OCCURRED ABOUT A MONTH AGO ANTILOCK BRAKES ARE APPLYING WHEN DRY. WHEN GOING ABOUT 3-4 MPH THE ANTILOCK BRAKES WILL ENGAGED. THIS PROBLEM WAS RANDOM. HAVE NOT TAKEN FOR REPAIRS. *NM

NHTSA ID

10119980

Incident

May 5, 2005

Mileage

34,600 mi

WHEN THE VEHICLE WAS STARTED IN THE MORNING, THE BRAKES MADE A GRINDING NOISE WHEN DEPRESSED. THE VEHICLE WAS SERVICED BY THE DEALERSHIP TWICE AND THEY REPLACED THE BRAKE DISC, ROTORS AND SHOES. WHILE DRIVING DOWN A HILL WITH THE BRAKE PEDAL DEPRESSED, THE BRAKE SYSTEM OVERHEATED, AND A BURNING ODOR FILLED THE CABIN OF THE VEHICLE. *AK THE BRAKES STARTED TO PULSATE AGAIN WHILE GOING DOWN A MOUNTAIN, A NOISE WAS HEARD COMING FROM THE DRIVELINE BETWEEN SHIFTS AND WAS UNABLE TO BE DUPLICATED, THE TRANSMISSION SLIPPED AND SHIFTED ERRATICALLY, THE ENGINE WOULD BREAK UP ON A SLIGHT ACCELERATION DUE TO THE DISTRIBUTOR CAP AND THE ROTOR BEING CORRODED. *SC *JB

NHTSA ID

10087155

Incident

Sep 30, 2003

Mileage

13,032 mi

WHILE DRIVING AT 5 MPH CONSUMER ATTEMPTED TO PARK IN THE DRIVEWAY AND WITHOUT WARNING LOST STEERING ABILITY. ALSO, BRAKES WERE INOPERABLE, AND WOULD NOT STOP THE VEHICLE. THE VEHICLE COLLIDED WITH THE OUTSIDE WALL OF THE GARAGE. THERE WAS CONSIDERABLE DAMAGE TO THE GARAGE AND THE VEHICLE. CONSUMER SUSTAINED NO BODILY INJURIES. *AK SLIDING DOOR DOESN'T UNLOCK TO OPEN. DEALER REPLACED PS PUMP BECAUSE PUMP DRIVE SHAFT WAS BROKEN, AND REINSTALLED SIDE DOOR. *LA

NHTSA ID

10061311

Incident

Feb 17, 2004

Mileage

26,000 mi

WHILE BRAKING ABS BRAKES FAILED, CAUSING EXTENDED STOPPING DISTANCE.*AK

NHTSA ID

10055523

Incident

Jan 7, 2004

Mileage

13,500 mi

VAN EXPERIENCED MULTIPLE BRAKE FAILURES BACK TO BACK. ON THREE SEPARATE OCCASIONS FRONT BRAKES WOULD SMOKE DUE TO BRAKE PADS MELTING. THE NEXT BRAKE FAILURE OCCURRED WHEN THE BRAKES FAILED TO STOP THE VAN IMMEDIATELY WHEN PEDAL WAS DEPRESSED WHILE GOING DOWN A HILL. THIS RESULTED IN EXTENDED STOPPING DISTANCE. DEALERSHIP SERVICED THE VAN, BUT FOUND NO PROBLEM WITH THE BRAKING SYSTEM. HOWEVER, BRAKE PROBLEM RECURRED FIVE MONTHS AFTERWARDS, AND ALMOST REAR ENDED ANOTHER VEHICLE.*AK

NHTSA ID

10044298

Mileage

4,000 mi

THE BRAKES MADE A SQUEALING NOISE, AND WAS REPLACED. AFTER THEY WERE REPLACED, THE BRAKES LOCKED UP WHICH RESULTED IN AN ACCIDENT. *JB WHEN THE BRAKES LOCKED, THE VEHICLE RAN INTO A SNOWBANK. ON THE SECOND OCCASION, THE BRAKES LOCKED AND SLID INTO THE PERSON IN FRONT. THE VEHICLE WAS REAR ENDED AND THE AIR BAGS DID NOT DEPLOY AND THE SEAT BELTS WERE INOPERATIVE. THE CONSUMER REQUESTED MONEY BACK. *SCC

NHTSA ID

10019695

Incident

Dec 23, 2002

Mileage

60,000 mi

THE BRAKE PEDAL WAS TO SMALL. WHEN THE CONSUMER APPLIED THE BRAKE, HER FOOT SLIPPED OFF THE BRAKE PEDAL. *NLM *TS *JB

NHTSA ID

10020151

Incident

May 18, 2003

WHEN THE BRAKES WERE APPLIED, THE PEDAL TRAVELED TO THE FLOOR. *JB ALSO LOST STEERING CONTROL. BLOWN POWER STEERING SHAFT SEAL HAD TO BE REPLACED. *TT

NHTSA ID

10015459

Incident

Apr 8, 2003

Mileage

7,200 mi

THE ABS SYSTEM FAILED AND CAUSED THE BRAKE PEDAL TO GO TO THE FLOOR. *NLM

NHTSA ID

10015345

CONSUMER STATED WHEN HE ATTEMPTED TO APPLY THE BRAKES, THE PEDAL WENT HALF WAY DOWN, IT WAS DISCOVERED THAT THERE WAS A FAULTY MAIN MODULE WHICH CONTROLLED THE BRAKE SYSTEM. DEALER HAS BEEN NOTIFIED. *JB THE VEHICLE LOST IT'S BRAKING POWER ON A STEEP ICY HILL AND SLID WITH THE PEDAL FULLY DEPRESSED. IMMEDIATELY AFTER THE VEHICLE WAS REPAIRED, THE BRAKE MODULAR HAD FAILED DURING A TEST DRIVE. *SCC

NHTSA ID

10003665

Incident

Jan 13, 2003