2003 Chevrolet Astro Brakes Problems

I WAS DRIVING PULLING A TRAILER ON THE FREEWAY WHEN SUDDENLY THE TRAFFIC STOP. I APPLIED THE BRAKES AT A SAFE DISTANCE WHEN SUDDENLY MY BRAKES WHEN ALL THE WAY TO THE FLOOR I APPLIED THE EMERGENCY BRAKES AND STOP. I HAD TO GO THRU THE EMERGENCY LANE. I TOLD MY SON TO PUSH THE BRAKE PEDAL WHILE I WAS UNDERNEATH AND THE BRAKE LINES BROKE. THEY WHERE ALL RUSTED OUT. I HAD TO GET A WRECKER TO TAKE IT HOME.IF YOU NEED TO SEE MY VAN CALL ME SO YOU CAN SEE THE BRAKE LINES. *TR

NHTSA ID

10594005

Incident

May 23, 2014

Mileage

96,500 mi

MY SPOUSE WAS DRIVING AND WE WERE STOPPED AT A YARD SALE. WE RETURNED TO THE VEHICLE AND STARTED TO BACK OUT WHEN SHE NOTICED THE STEERING WHEEL WAS EXTREMELY HARD TO TURN. THEN WHEN SHE WANTED TO STOP THE VEHICLE THE BRAKES WERE EXTREME HARD TO OPERATE. AFTER SOME RESEARCH WE LEARNED OF HUNDREDS OF BRAKE MALFUNCTIONS ON SIMILAR VEHICLES AND OTHER CARS THAT USE SIMILAR BRAKE BOOSTER TECHNOLOGY. *TR

NHTSA ID

10577639

Incident

Apr 5, 2014

Mileage

150,000 mi

I AM COMPLAINING OF THE SAFETY ISSUES REGARDING THE ABS COMPUTER SYSTEM. I HAVE PUT MY VEHICLE IN THE SHOP TO BE CHECKED OUT BY A FEW CAR REPAIR FACILITIES AND ALL HAVE SAID THE SAME THING MY ABS CPU. MY VAN IS HESITATING TERRIBLY AND CAUSING THE VAN TO NOT ACCELERATE PROPERLY. I HAVE NEARLY BEEN IN THREE ACCIDENTS SINCE THE PROBLEM HAS BEEN OCCURRING. I HAVE ALSO DONE SOME RESEARCH ON THIS ISSUE VIA INTERNET AND FOUND THAT MANY PEOPLE ARE HAVING THE SAME PROBLEM ACROSS THE USA. AND GM IS BLAMING IT ON THE WEATHER CONDITIONS IN THE NORTH BUT THE PROBLEMS ARE HAPPENING TO ASTRO VANS(2003) ACROSS THE ENTIRE US. THIS IS A PROBLEM THAT SHOULD BE ADDRESSED AS SOON AS POSSIBLE.. THE CONTACT STATED WHILE APPLYING BRAKE PRESSURE AT 20MPH OR LESS, THE ABS ACTIVATED WITH AN INCREASED STOPPING DISTANCE. THE VEHICLE WAS SEEN BY AN INDEPENDENT REPAIR SHOP. A DIAGNOSTIC TEST WAS PERFORMED WHICH INDICATED A FAILURE IN THE RIGHT FRONT WHEEL SPEED SENSOR. THE MECHANIC DETERMINED THE WHEEL SPEED SENSOR OF THE ANTILOCK BRAKES NEEDED TO BE REPLACED. THERE IS A NHTSA RECALL, # 05V379000, REGARDING THE ANTILOCK BRAKES. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER IT IS NOT INCLUDED IN THE RECALL DUE TO THE VIN. THIS VEHICLE CURRENTLY HAS THIS ISSUE, AND WAS CHECKED BY A REPAIR SHOP. THEY DESCRIBED THE PROBLEM UNDETECTABLE; THE RECALL WAS ON MODELS UP TO 2002. IT SEEMS THAT IT CARRIED OVER TO THIS MODEL, CAN THE DEALER ASSIST IN REPLACING THE PARTS. I WOULD PAY THE LABOR BUT THE PARTS INVOLVED ARE ABOUT $1500.00 FROM THE DEALER ALONE. CAN I GET HELP FROM THE NHTSA TO GET THIS CRITICAL ISSUE RESOLVED. *TR

NHTSA ID

10547421

Incident

Oct 9, 2013

Mileage

50,000 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET ASTRO VAN. THE CONTACT STATED THAT THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOOR WHILE MAKING A LEFT TURN. THE CONTACT ALSO STATED THAT THE VEHICLE FAILED TO START WHEN THE VEHICLE WAS PARKED AND THE WHEELS WERE TURNED TO THE LEFT. A MECHANIC LOOKED UNDER THE VEHICLE AND FOUND THAT THE WIRING HARNESS THAT WAS LOCATED NEAR THE FRONT PASSENGER SIDE TIRE HAD BURNED OUT. THE VEHICLE WAS TAKEN TO THE DEALER BUT THE CONTACT WAS UNSURE OF WHAT WOULD BE REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN BUT THE CURRENT MILEAGE WAS 67,000. *TR

NHTSA ID

10526083

Incident

Jul 14, 2004

Mileage

67,000 mi

COMPLETE BRAKE FAILURE DUE TO RUSTING BRAKE LINES. THE PREVIOUS DAY THIS VEHICLE WAS PULLING A SMALL TRAILER ON A MICHIGAN INTERSTATE HIGHWAY. THE FOLLOWING DAY IT WAS PARKED IN MY DRIVEWAY AND A WET AREA WAS VISIBLE ON THE CONCRETE. IT WAS BRAKE FLUID ON THE GROUND THAT HAD DRIPPED FROM THE RUSTED BRAKE LINE AND DRAINED THE MASTER CYLINDER RESERVOIR. I DISCOVERED THIS WHEN MOVING THE VEHICLE TO TRY AND DETERMINE THE CAUSE OF THE FLUID LEAK. THE BRAKE LINE HAD COMPLETELY RUSTED THROUGH! FORTUNATELY THIS DID NOT HAPPEN THE PREVIOUS DAY AS IT COULD EASILY HAVE BEEN FATAL. THE VEHICLE WAS TOWED TO THE GM DEALERSHIP. THERE ARE NO REPLACEMENT PARTS FOR THE BRAKE LINES AND NONE ARE AVAILABLE IN THE AFTERMARKET. THE DEALER WANTED OVER $1700 TO REPLACE THE LINES AND SAID THERE MAY BE MORE ITEMS TO REPLACE - POSSIBLY ANOTHER $700 OR MORE. PLUS, FUEL LINES WERE ALSO RUSTING AND THEY SHOULD BE REPLACED TOO. THIS COULD EASILY HAVE BEEN A FATAL INCIDENT OR EXTREME DAMAGE AS THE BRAKES WERE COMPLETELY USELESS IN MY DRIVEWAY AND I HAD TO PUT THE VEHICLE INTO REVERSE TO STOP IT, EVEN AT A VERY SLOW SPEED. I HAVE HAD OTHER VEHICLES FOR A MUCH LONGER TIME - INCLUDING GM - AND NEVER HAD ANYTHING LIKE THIS BEFORE. *TR

NHTSA ID

10471363

Incident

Aug 13, 2012

Mileage

80,000 mi

I WAS DRIVING APPROXIMATELY 30 MILES PER HOUR ALONG SLIGHTLY SNOW-COVERED ROAD TOWARDS STOPPED TRAFFIC AT RED LIGHT ON A SLIGHT DOWNGRADE. I STEPPED ON THE BRAKES GENTLE, AS REQUIRED BY THE CONDITIONS, BUT THE ABS SYSTEM STARTED TO SHUDDER AND THE VEHICLE DID NOT BRAKE AT ALL. I HIT A STOPPED VEHICLE AT THE INTERSECTION AND EVEN WITH A RELATIVELY SLOW SPEED IMPACT, OUR VEHICLE WAS WRITTEN OFF AND THE OTHER WAS TOWED AWAY BECAUSE IT COULD NOT BE DRIVEN. OUR VAN WAS DRIVABLE, BUT JUST BARELY, AND WAS SUBSEQUENTLY WRITTEN OFF BY THE INSURANCE COMPANY. I WAS CHARGED WITH CARELESS DRIVING WHICH WAS ABSOLUTELY NOT THE CASE. WE HAVE ANOTHER VEHICLE OF THE SAME YEAR AND SIMILAR MODEL AND IT DOES THE SAME THING OCCASIONALLY BUT SO FAR THIS HAS NOT RESULTED IN ANY FURTHER COLLISIONS. WE HAVE OWNED ASTRO VANS SINCE THEY WERE FIRST MARKETED IN 1985 AND THIS IS THE FIRST ONE TO ACT LIKE THIS. WE PURCHASED 1985, 1992, 1998, AND 2003 MODELS (2). I AM ASKING MY WIFE, ROSE, WHO IS ALSO THE REGISTERED OWNER OF THE VEHICLE TO SUBMIT THIS REPORT ON MY BEHALF. PLEASE RESPOND TO HER WITH ANY RESOLUTIONS. WE PURCHASED THE SALVAGE FROM THE INSURANCE COMPANY SO IT IS STILL IN OUR POSSESSION ALTHOUGH NOT ON THE ROAD. *TR

NHTSA ID

10308449

Incident

Feb 6, 2009

Mileage

173,000 mi

VEHICLE: 2003 CHEVY ASTRO VAN DEFECT SUMMARY: FACTORY DESIGN DIRECTS LEAKED BATTERY ACID TO DRIP DOWN ON A STEEL BRAKE LINE. DETAILS: THE (+) BATTERY TERMINAL SPONTANEOUSLY BROKE OFF THIS VEHICLE'S OEM DELCO BATTERY. THE BREAKAGE WAS DUE TO EITHER: 1) CABLE CONNECTOR BEING OVER-TORQUED AT THE GM FACTORY, OR 2) AN INTEGRAL FAULT WITHIN THE BATTERY. THE DESIGN OF THIS YEAR-MODEL OF ASTRO IS SUCH THAT THE NATURAL PATH FOR ACID DRIP-PAGE IS ON TO A STEEL BRAKE LINE LOCATED BELOW, AND IN FRONT, OF THE BATTERY. I AM GOING TO HAVE THE BRAKE LINE REPLACED BY A LOCAL CERTIFIED MECHANIC BECAUSE THE LINE IS SEVERELY CORRODED DUE TO THE ACID EXPOSURE. BECAUSE OF THE INACCESSIBILITY OF THE BRAKE LINE AND ITS CONNECTIONS, THE REPAIR COST WILL NOT BE CHEAP. PLEASE NOTE THAT THE BATTERY AND CABLE HAVE NOT BEEN EXPOSED TO ANY POST-MANUFACTURE MISUSE OR DISTURBANCE. THE PROBLEM IS SOLELY DUE TO POOR PLACEMENT OF THE HYDRAULIC LINE, COUPLED WITH THE FACTORY INDUCED BATTERY BREAKAGE. I HAVE DIGITAL PHOTOGRAPHS FOR YOUR INSPECTION OF THE BROKEN BATTERY TERMINAL, THE GEOMETRY OF THE BATTERY COMPARTMENT, THE (BRAKE) HYDRAULIC LINE, AND THE RESULTING CORROSION. *TR

NHTSA ID

10269522

Incident

May 20, 2009

Mileage

31,346 mi

THE BRAKE LINE RUBBED UP AGAINST THE POWER STEERING PUMP, EVENTUALLY RUBBING THROUGH. I LOST BRAKING POWER AND NEARLY CAUSED AN ACCIDENT. WITHIN MINUTES, I WENT FROM HAVING BRAKES TO HAVING TO PUSH THE BRAKE PEDDLE TO THE FLOOR TO STOP. I HAD A LOCAL MECHANIC FIX THE PROBLEM AT A SUBSTANTIAL COST. *TR

NHTSA ID

10254819

Incident

Jan 1, 2009

Mileage

145,000 mi

2003 CHEVROLET ASTRO WITH BRAKE PROBLEMS. CONSUMER STATES THAT GM WILL NOT REIMBURSE HER FOR THE REPAIRS MADE ON HER VEHICLE. *KB THE CONSUMER STATED WHILE BRAKING AT LOW SPEEDS, THE VEHICLE LUNGED FORWARD. ALSO, THE ABS LIGHT ILLUMINATED. THE CONSUMER HAD TO PAY TO HAVE THE SENSORS REPLACED. *JB

NHTSA ID

10254528

Incident

Jan 1, 1901

ON SEVERAL OCCASIONS OVER THE PAST FEW MONTHS, THE ABS LIGHT ON MY VAN HAS BEEN COMING ON AND WHEN I APPLY THE BRAKES, THE VAN JERKS AROUND ON THE ROAD AND PULLS TO THE LEFT. I HAVE ALMOST HIT OTHER CARS ON MANY OF THESE OCCASIONS. I HAD MY MECHANIC LOOK AT IT RECENTLY AND HE SAID HE CHECKED OUT THE BRAKING SYSTEM AND CAN SEE NO VISIBLE REASON FOR THIS HAPPENING. *TR

NHTSA ID

10238956

Incident

May 1, 2008

Mileage

95,000 mi

SUMMARY: ON 2003 CHEVY MINIVAN, THE MULTIFUNCTION SWITCH HS DEVELOPED AN OPEN CIRCUIT CONDITION IN THE STOP LAMP OR HAZARD LAMP CIRCUIT THAT RESULTS IN THE STOP LAMPS AND HAZARD LAMPS BEING INOPERATIVE. CONSEQUENCE: THE LOSS OF STOP LAMPS AND REAR HAZARD LAMPS COFAILED TO WARN THE FOLLOWING DRIVER THAT THE VEHICLE IS BRAKING AND/OR IS STOPPED AND COULD HAVE LEAD TO A VEHICLE CRASH. REMEDY: DEALERS ARE REPLACING 2002 CHEVY ASTRO HAZARD WARNING FLASHER SWITCH FREE OF CHARGE, BUT NOT 2003 ASTROS THAT HAVE THE SAME MANUFACTURER DEFECT. THE RECALL BEGAN ON APRIL 13, 2005 FOR OWNERS OF 2002 CHEVY ASTROS. GM RECALL NO. 05013. *TR

NHTSA ID

10218875

Incident

Feb 22, 2008

Mileage

70,000 mi

BRAKE LIGHTS WOULD NOT WORK. AFTER A FEW HOURS OF TROUBLESHOOTING, I ISOLATED THE PROBLEM TO A DEFECTIVE HAZARD SWITCH. IF PUSHED TO THE LEFT, THE BRAKE LIGHTS WORKED. I PLAN ON TRYING TO FIX IT TOMORROW, BUT SAW THAT THERE IS A RECALL ON 2001 AND 2002, BUT NOT ON 2003. MY VAN WAS BUILT IN LATE 2002. NO DOUBT IT HAS THE SAME DEFECTIVE SWITCH. VERY DANGEROUS SITUATION CAN OCCUR ON THE UPDATED 01/02/08.*JB

NHTSA ID

10201078

Incident

Aug 28, 2007

Mileage

90,000 mi

ABS LIGHT ON WITH MULTIPLE CODES AND ABS BRAKES ARE ACTIVATING AT SLOW SPEEDS ON DRY PAVEMENT WHEN THE SHOULDN'T BE, CAUSING AN INCREASING STOPPING TIME AND NEAR MISS ACCIDENT.*AK

NHTSA ID

10190865

Incident

Apr 25, 2007

Mileage

80,000 mi

SHUDDER AND/OR ABS ACTIVATION DURING LOW SPEED TURNS, MAINLY TO THE LEFT. VEHICLE IS AN 03 ASTRO VAN AWD WITH 67K MILES. VEHICLE PULLS PRETTY SHARPLY LEFT WHEN THIS OCCURS. *JB

NHTSA ID

10189686

Incident

May 2, 2007

Mileage

67,800 mi

I AM COMPLAINING OF THE SAFETY ISSUES REGARDING THE ABS COMPUTER SYSTEM. I HAVE PUT MY VEHICLE IN THE SHOP TO BE CHECKED OUT BY A FEW CAR REPAIR FACILITIES AND ALL HAVE SAID THE SAME THING MY ABS CPU. MY VAN IS HESITATING TERRIBLY AND CAUSING THE VAN TO NOT ACCELERATE PROPERLY. I HAVE NEARLY BEEN IN THREE ACCIDENTS SINCE THE PROBLEM HAS BEEN OCCURRING. I HAVE ALSO DONE SOME RESEARCH ON THIS ISSUE VIA INTERNET AND FOUND THAT MANY PEOPLE ARE HAVING THE SAME PROBLEM ACROSS THE USA. AND GM IS BLAMING IT ON THE WEATHER CONDITIONS IN THE NORTH BUT THE PROBLEMS ARE HAPPENING TO ASTRO VANS(2003) ACROSS THE ENTIRE US. THIS IS A PROBLEM THAT SHOULD BE ADDRESSED AS SOON AS POSSIBLE.. *JB

NHTSA ID

10186608

Incident

Mar 29, 2007

Mileage

100,000 mi

TL* - THE CONTACT HAS A 2003 CHEVROLET ASTRO VAN WHICH HAS BEEN IN THE DEALER SERVICE SHOP SINCE DECEMBER 19, 2006. WHEN DRIVING AND TURNING THE VEHICLE LOST POWER IN BOTH THE STEERING SYSTEM AND THE BRAKES. THE DEALER RAN THE VEHICLE TROUGH DIAGNOSTIC TESTS, AND COULD NOT DETERMINE THE CAUSE OF THE FAILURE. THE CONTACT FOUND RECALL INFORMATION FOR VEHICLES WITH SIMILAR FAILURES. ON DECEMBER 29 2006 THEY RECEIVED A CALL FROM THE DEALER STATING THAT THEY WERE CHECKING TO SEE IF THE PROBLEM WAS COVERED UNDER THE VEHICLE'S WARRANTY IF NOT THE COST OF THE REPAIR WILL BE $552.10. *AK

NHTSA ID

10177708

Incident

Dec 19, 2006

Mileage

115,819 mi

DT*: THE CONTACT STATED WHILE BRAKING, THE ABS LIGHT ILLUMINATED AND THERE WAS A PULSATING EFFECT WITH THE BRAKE PEDAL. THE VEHICLE WAS TAKEN TO THE DEALER WHO DETERMINED THE LEFT HUB AND SENSOR HAD TO BE REPLACED. THE PROBLEM RECURRED 5000 MILES LATER. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHERE THE RIGHT SENSOR AND HUB NEEDED TO BE REPLACED ALONG WITH THE CONTROL MODULE OF THE WHOLE ABS SYSTEM. THE MANUFACTURER WAS CONTACTED AND AGREED TO PAY FOR HALF OF THE REPAIRS. UPDATED 11/09/06. *JB

NHTSA ID

10170966

Incident

Sep 5, 2006

Mileage

48,000 mi

DT: THE CONTACT STATED THE ABS SENSOR BECAME DEFECTIVE AT 45,000 MILES. WHILE DEPRESSING THE BRAKES AT LOW SPEEDS, THE VEHICLE COASTED. ON ONE OCCASION THE VEHICLE COLLIDED WITH THE CURB WHICH COULD HAVE CAUSED A COLLISION. DURING THESE INCIDENTS THE ABS LIGHT ILLUMINATED INTERMITTENTLY. THE VEHICLE HAS BEEN TAKEN TO TWO INDEPENDENT REPAIR SHOPS WHO CONFIRMED THAT THE ABS SENSOR IS DEFECTIVE. THEY ALSO RECOMMENDED REPLACEMENT OF THE ABS SENSOR. THE CONTACT EXPRESSED THAT THE ABS SENSOR FAILED LONG BEFORE WHAT WAS REASONABLE. *NM

NHTSA ID

10163306

Incident

Jul 23, 2006

Mileage

68,000 mi

MY WIFE AND I WERE DRIVING ALONG WHEN THE BRAKE SYSTEM WENT COMPLETELY OUT. WE HAD JUST PURCHASED THE VAN ABOUT 4-5 MONTHS BEFORE IT HAPPENED. I HAD THE VAN LOOKED AT BY JAMES MARTIN CHEVROLET IN DETROIT MICHIGAN. THE REPAIRS CAME UP TO $1400.00. THE VAN ONLY HAD ABOUT 40,000 MILES ON IT. *NM

NHTSA ID

10161003

Incident

Jun 5, 2005

Mileage

40,000 mi

WHILE BRAKING AT LOW SPEED ABS ACTIVATES INCREASING STOPPING DISTANCE ALMOST CAUSING ACCIDENT WEATHER NOT A FACTOR ROAD CONDITION NOT A FACTOR ALSO HAPPENS DURING PARKING LOT MANEUVERS TURNING INTO PARKING SPOTS ABS ACTIVATES AND SEEMS NOT TO STOP NOTE: THIS IS AN 2003 ALL WHEEL DRIVE ASTRO VAN. *NM

NHTSA ID

10155882

Incident

Apr 19, 2006

Mileage

30,000 mi

DT*: THE CONTACT STATED WHILE APPLYING BRAKE PRESSURE AT 20MPH OR LESS, THE ABS ACTIVATED WITH AN INCREASED STOPPING DISTANCE. THE VEHICLE WAS SEEN BY AN INDEPENDENT REPAIR SHOP. A DIAGNOSTIC TEST WAS PERFORMED WHICH INDICATED A FAILURE IN THE RIGHT FRONT WHEEL SPEED SENSOR. THE MECHANIC DETERMINED THE WHEEL SPEED SENSOR OF THE ANTILOCK BRAKES NEEDED TO BE REPLACED. THERE IS A NHTSA RECALL, # 05V379000, REGARDING THE ANTILOCK BRAKES. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER IT IS NOT INCLUDED IN THE RECALL DUE TO THE VIN.

NHTSA ID

10155813

Incident

Apr 21, 2006

Mileage

62,000 mi

DT*: THE CONTACT STATED WHILE BRAKE PRESSURE WAS APPLIED AT 15MPH, A GRINDING NOISE WAS HEARD COMING FROM THE BRAKES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP FOR INSPECTION. THE MECHANIC DETERMINED THE ROTORS HAD RUSTED DUE TO THE VEHICLE BEING IN SALT BELT STATE. THE ROTORS WERE REPLACED AND THE VEHICLE NOW OPERATES NORMALLY. THE MECHANIC STATED THE ROTORS WERE MADE WITH INFERIOR METAL. UPDATED 05/02/06. *JB

NHTSA ID

10153781

Incident

Dec 15, 2005

Mileage

29,000 mi

I HAVE REPORTED THIS BEFORE DUE TO SEVERAL OTHER CLOSE CALLS THAT I HAD, BUT THE SAME THING HAS HAPPENED TO TWO OTHERS IN THE SAME VEHICLE. WHEN DEPRESSING THE BRAKE PEDAL (BECAUSE IT IS SO SMALL - 2"X2.6") YOUR FOOT CAN BE ON THE EDGE OF THE PEDAL AND IT WILL SLIP OFF AS YOU APPLY MORE PRESSURE. THIS HAPPENS WHEN YOU ARE NEARING A STOP OR HAVING TO MAKE A QUICK STOP. WE HAVE HAD SEVERAL NEAR MISS ACCIDENTS, THE LAST WOULD HAVE BEEN A RIGHT ANGLE COLLISION WITH A DUMP TRUCK RIGHT IN THE DRIVER'S DOOR. THE VEHICLE IS A 2003 ASTRO VAN WITH AUTOMATIC TRANSMISSION. FOOT SPACE IS LIMITED ONLY IF IT WOULD BE A STICK SHIFT REQUIRING A CLUTCH. THE BRAKE PEDAL IS THE SMALLEST IN OUR FLEET AND NOT MUCH LARGER THAN THE EMERGENCY BRAKE PEDAL. THE VEHICLE IS NOW PARKED PENDING A SAFETY REVIEW. *NM

NHTSA ID

10152944

Incident

Mar 14, 2006

Mileage

21,865 mi

DT*:THE CONTACT STATED WHILE STOPPING IN A PARKING LOT THE ABS LIGHT ILLUMINATED AND THE BRAKE PEDAL BECAME HARD TO DEPRESS. ONCE THE VEHICLE BEGAN TO ACCELERATE A NOISE CAME FROM THE ABS. THE NOISE CEASED AT APPROXIMATELY 20 MPH. ADDITIONALLY, THE ABS LIGHT ILLUMINATED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO THE DEALERSHIP, THEY ONLY RAN THE VIN TO CHECK FOR RECALLS. IT WAS ALSO SEEN BY A INDEPENDENT REPAIR SHOP WHO DETERMINED THERE WAS NO PROBLEM WITH THE ANTI LOCK BRAKING SYSTEM. *AK

NHTSA ID

10146339

Incident

Aug 1, 2005

ON SEPTEMBER 9, 2005 MY 2003 CHEVROLET ASTRO VAN EXPLODED AND CAUGHT FIRE IN A PARKING LOT. THE FIRE DEPT. ARRIVED AND PUT OUT THE FIRE; THE FIREMEN DISCONNECTED THE BATTERY CABLE. THE VAN WAS TOWED TO HUFFINES CHEVROLET IN PLANO, TX. THE CAUSE OF THE INCIDENT ACCORDING TO THE CHEVROLET MECHANICS IS AS FOLLOWS: 1) EVERY TIME THE STEERING WHEEL WAS TURNED, THE TIE RODS ETC. WOULD CHAFE AGAINST A BRACKET ON THE CHASSIS THAT HELD DOWN A BATTERY CABLE. 2) EVENTUALLY THE BRACKET FAILED. 3) THE BATTERY CABLE ARCED AGAINST THE BRAKE LINE. 4) THE BRAKE LINE RUPTURED SPRAYING HYDRAULIC FLUID OVER THE HOT ENGINE MANIFOLD. 5) THE ENSUING FIRE BURNED THROUGH, AMONG OTHER THINGS, THE A/C HOSE CARRYING FREON. 6) WHEN THE A/C HOSED WAS SEVERED, THE FREON GAS ESCAPED CAUSING THE LOUD EXPLOSION THAT WE HEARD SOME DISTANCE AWAY. 7) THE SMOKE THAT WE SAW IN THE AIR WAS ACTUALLY THE ESCAPING FREON GAS. ALL WAS SUPPOSEDLY REPAIRED IN THREE WEEKS. ON NOVEMBER 8, 2005, THE BRAKES FAILED WHILE UNDER WAY. THE CHEVROLET MECHANICS STATED THAT THE CAUSE OF THE BRAKE FAILURE WAS TRACED TO A SMALL PINHOLE CAUSED BY THE ARCING BATTERY CABLE SEVERAL WEEKS AGO. EVENTUALLY THE ENTIRE BRAKE LINE FAILED. IF THIS STORY SEEMS PREPOSTEROUS TO YOU, IT DOES TO ME TOO BUT THIS IS THE STORY WE GOT FROM CHEVROLET. IN MY OPINION, MY 2003 CHEVY ASTRO VAN SUFFERS FROM A FATAL FLAW IN DESIGN AND/OR MANUFACTURER. IT IS UNSAFE AND SHOULD BE TAKEN OFF THE ROAD FOREVER. *JB

NHTSA ID

10142603

Incident

Sep 9, 2005

Mileage

30,900 mi