RoadVitals

2004 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.
14
Latest Apr 21, 2020
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.
2
Latest May 19, 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.
0
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.
2
3 injuries, 0 deaths reported

Overview

Our database contains 14 NHTSA owner-reported complaints for the 2004 Chevrolet Astro, most frequently naming the brakes, electrical and driver assistance categories. 2 safety recalls have been issued covering this model year; and 409 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

  • Brakes741.2%
  • Electrical211.8%
  • Driver assistance211.8%
  • Interior & seats15.9%
  • Suspension15.9%
  • Airbags15.9%
  • Visibility15.9%
  • Engine15.9%

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

2 campaigns cover this model year

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
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

Recent owner complaints

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

View all 14
Driver assistance
Filed Apr 21, 2020

ONCE OR TWICE PER YEAR WHEN USING CRUISE CONTROL, WHEN I TOUCH BRAKE TO DEACTIVATE CRUISE, IT DOESN'T DISENGAGE. I THEN HAVE TO STAND ON BRAKE WITH ALL MY EFFORT TO STOP VAN AND PULL OVER TO PUT IN PARK. ENGINE CONTINUES RACING TIL I TURN KEY OFF. THEN EVERYTHING OK TIL NEXT TIME MAYBE MONTHS LATER. SWITCK ON BRAKE PETAL IS OK. ONCE IN THE WINTER, CRUISE CONTROL PUSHED ME INTO AN INTERSECTION. LUCKILY OTHER TRAFFIC REALIZED I COULDN'T STOP. NO CODES SHOW UP TO IDENTIFY CAUSE. BEEN DOING THIS 4 OR 5 YEARS INTERMITTENTLY. EVEN THO THIS VAN IS 16 YEARS OLD, IT ONLY 6HAS 90000 MILES ON IT. I TRY NOT TO DRIVE IT MUCH BECAUSE OF THIS PROBLEM. MY BEST GUESS IT'S MECHANICAL OR COMPUTER PROBLEM BUT SINCE IT HAPPENS SO SELDOM HARD TO DIAGNOSE.I HAVE ANOTHER ASTRO 5 YR OLDER WITH 230000 ON IT AND CRUISE WORKS LIKE IT SHOULD. I HAVE NO MORE INFORMATION.

NHTSA ID
11321778
Incident
May 22, 2015
Mileage
70,000 mi
Brakes
Filed May 19, 2015

ANTILOCK BRAKING SYSTEM WARNING LIGHTS AND BRAKE LIGHT CAME ON WHEN I WAS ENTERING THE FREEWAY. THE LIGHTS CONTINUE TO COME ON WHENEVER I AM DRIVING. I HAD IT CHECKED AT CORNING CHEVROLET AND WAS TOLD THE PART ALONE WAS $900 PLUS LABOR TO REPLACE IT. THE BRAKES WORK, BUT NOT THE ANTILOCK SYSTEM INSTALLED BY THE MANUFACTURER.

NHTSA ID
10717422
Incident
May 18, 2006
Mileage
50,500 mi
Brakes
Filed Apr 9, 2015

WE LIVE IN THE COUNTRY WITH GRAVEL ROADS. ALL OF OUR CHEVROLET VEHICLES HAVE HAD BRAKE LINES ROT OUT. OUR FORD AND DODGE VEHICLES HAVE NOT. THE CHEVROLET ASTRO VANS WE HAVE EXHIBIT A PROPENSITY FOR THE BRAKE LINE ROTTING OUT OVER THE GAS TANK AS WELL AS THE BRAKE LINES OVER THE FRONT FRAME MEMBERS. THE BRAKE LINES ON 20 YEAR OLD FORD VEHICLES LOOK AS GOOD AS NEW UNDER THE SAME CONDITIONS. MY 1994 CHEVROLET K-3500 PICKUP HAS BLOWN BRAKES LINES DUE TO ROT ALONG WITH THE BACK PART OF THE FRAME THAT RUSTED OUT. I JUST READ WHERE YOU HAVE ADVISED WASHING THE UNDERSIDE OF CHEVROLET VEHICLES SEVERAL TIMES A YEAR. WELL THE LINES ROTTING OUT ON TOP OF THE GAS TANK AND THE FRONT FRAME RAILS WILL NOT GET WASHED. WHOEVER MADE THE "WASH IT" DECISION EVIDENTLY DOES NOT DRIVE OLDER CHEVROLETS. IF THERE WAS NO PROBLEM THEN WHY DID CHEVROLET EVIDENTLY CHANGE THEIR LINES? OR MAYBE THEY DID NOT AND THE NEWER ONES JUST HAVE NOT STARTED ROTTING OUT YET. WHY DO FORD BRAKE LINES, EXHAUST SYSTEMS, FRAMES, AND BODIES NOT RUST LIKE GM. SOMEONE IS HIDING SOMETHING. THE CHEVROLET BRAKE LINE ARE DEFINITELY A SAFETY HAZARD DUE TO RUSTING THRU. *TR

NHTSA ID
10704745
Incident
Apr 16, 2014
ElectricalEngineFuel system
Filed Jun 20, 2014

TL* THE CONTACT OWNS A 2004 CHEVROLET ASTRO. THE CONTACT STATED THAT THE VEHICLE FAILED TO START UNTIL AFTER THREE ATTEMPTS. THE CONTACT SHIFTED INTO DRIVE AND THEN THE VEHICLE LOST ALL POWER. THE CONTACT PUMPED THE ACCELERATOR PEDAL, WAITED TEN MINUTES AND THE VEHICLE RESUMED ITS NORMAL OPERATION. THE FAILURE OCCURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE DEALER DIAGNOSED THE FAILURE AND STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE DEALER ASSURED THE CONTACT THAT AFTER PAYING FOR THE REPAIR, THE FAILURE WOULD BE RESOLVED. THE FUEL PUMP, STARTER, MOTOR MOUNTS, AND GENERATOR WERE ALL REPLACED; HOWEVER, THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 133,000. THE CURRENT MILEAGE WAS 134,249.

NHTSA ID
10604713
Incident
Jun 14, 2013
Mileage
133,000 mi
Brakes
Filed Dec 4, 2011

IT STARTED WITH MY ABS BRAKE LIGHT COMING ON AND STAYING ON. THEN I STARTED TO ENCOUNTER ANTI LOCK PULSATIONS WHEN I SLOWED DOWN AND COMING TO A STOP, SOME TIMES I COULDN'T EVEN STOP WHEN & WHERE I WANTED. BRAKING DISTANCE STARTED BEING LONGER. THEN SOME TIME LATER I FELT AS THOUGH SOMEONE STUCK A BRICK UNDER MY BRAKE PEDAL BECAUSE NO MATTER HOW HARD I PRESS, I GUARANTEE YOU, I COULDN'T STOP. THANK GOD NO ONE WAS IN FRONT OF ME AS I CRUISED ON THOUGH THE STOP LIGHT! I WAS TOLD THAT MY ABS SENSORS WERE SLOWLY MALFUNCTIONING MOST LIKELY DUE TO CORROSION, A PROVEN DESIGN DEFECT. THEN MY ABS MODULE WILL GET SHORTED, AND THERE IS NO FAIL/SAFE WHEN IT GOES. I WAS TOLD THAT WHEN THE MODULE FAILS, HANG ON BECAUSE I WILL CRASH. THIS SCARES ME TO DEATH AND I WONT LET ANYBODY DRIVE MY VAN IN CASE THIS HAPPENS WHEN THEY ARE DRIVING. ALSO WHEN WE WANT TO TAKE A TRIP I DON'T WANT TO TAKE MY VAN BECAUSE I'M AFRAID 6 TO 8 PEOPLE COULD GET HURT AND IT WOULD BE ON ME. EVERY REASON I BOUGHT THIS AWD VAN IS COMPLETELY OUT THE WINDOW. I CANT SELL IT BECAUSE OF THE BRAKE PROBLEM. I'M STUCK WITH A VAN THAT I CANT USE. I'M WRITING THIS BECAUSE WHEN I WENT TO GET THE ABS SERVICED I FIND OUT THAT I COULD WRITE A COMPLAINT ABOUT THE PROBLEM ( I DIDN'T EVEN KNOW YOU COULD DO THAT ) BECAUSE SOMETHING ABOUT A COMMUNICATION PROBLEM TO THE ABS MODULE SINCE 1999. AND THAT THEY RECALLED THE CHEVY TRUCKS THAT HAD THE SAME PROBLEM YEARS AGO. I WOULD THINK YOU WOULD FIX THE VANS BEFORE THE TRUCKS, BECAUSE TRUCKS DON'T CARRY A LOT OF PEOPLE! THEY CARRY WOOD. WHEN EVER I DRIVE THIS VAN NOW, I CONSIDER IT A RUSSIAN ROULETTE. I CANT AFFORD THE 2200.THAT WAS ESTIMATED TO FIX IT. I HAVE ALWAYS BELIEVED IN CHEVY, BUT I CANT BELIEVE THAT I DRIVE AFRAID EVERY DAY. I CANT BELIEVE THAT CHEVY KNOWS ABOUT THIS PROBLEM. *TR

NHTSA ID
10438527
Incident
Sep 19, 2002
Mileage
121,000 mi
Brakes
Filed Apr 17, 2011

I HAVE AN '04 CHEVY ASTRO VAN WITH ~ 88K MILES. IT IS SERVICED EVERY 3,000 MILES. RECENTLY, MY BRAKES FAILED. THE CAUSE WAS A WORN BRAKE LINE NEAR THE LEFT FRONT WHEEL. IT HAD RUBBED A HOLE IT THE LINE AND I LOST ALL THE BRAKE FLUID. *TR

NHTSA ID
10396579
Incident
Feb 15, 2011
Mileage
86,000 mi
Suspension
Filed Mar 31, 2011

AS I WAS DRIVING OVER SOME RAILROAD TRACKS BOTH OF MY FRONT TORSION BARS FAILED AND BROKE. HAD I BEEN TRAVELING ON THE INTERSTATE, IT COULD HAVE BEEN FATAL. FROM MY ONLINE RESEARCH, THIS SAME FAILURE HAS HAPPEND TO THOUSANDS OF OWNERS AND NO RECALL WAS DONE. GM EVEN REDESIGNED THE TORSION BARS BECAUSE OF THE KNOWN DESIGN FLAWS AND IT WILL COST WELL OVER $1,000 TO REPAIR. *TR

NHTSA ID
10393859
Incident
Mar 30, 2011
Mileage
256,000 mi
Brakes
Filed Aug 12, 2010

1. I PARKED MY WIFE'S VAN AT THE NEIGHBOR'S HOUSE BECAUSE GUESTS WERE ABOUT TO ARRIVE. THEIR DRIVEWAY IS ON A SLIGHT INCLINE SO I ENGAGED THE EMERGENCY BRAKE. 2. IT OCCURRED JUST ONCE WITH THE PEDAL GOING COMPLETELY TO THE FLOOR. 3. AFTER CONTACTING GM AND BEING DENIED COMPENSATION DUE TO NO RECALL AND THE AGE OF THE VEHICLE I PURCHASED AND REPLACED THE BROKEN DRIVER SIDE EMERGENCY BRAKE CABLE MYSELF. I BELIEVE THE CAUSE WAS A DESIGN FLAW. I HAVE THE OLD PART IF NEEDED FOR EXAMINATION. THE CABLE WAS COMPLETELY SEVERED DUE TO A CRACK IN THE OUTER SHEATH ALLOWING MOISTURE TO ENTER AND TO DETERIORATE THE CABLE. THE CRACK OCCURRED AT A SEVERE BEND WHERE A BRACKET SECURED THE CABLE TO THE FRAME OF THE VEHICLE. *TR

NHTSA ID
10349103
Incident
Jul 14, 2010
Mileage
131,193 mi

Manufacturer communications

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

PIP5601C

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

PIP5358D

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

PIP4723J

ELECTRICAL SYSTEM

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester  and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.

PIT5099H

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

PIT5099H

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

PIT3271P

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

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—
2004Viewing142048.0
2003623050.3
2002703157.1
2001913156.9
20001752052.9
19991334054.3
19982416054.3
19973607156.5
19962637155.0
19954467363.5
19943286160.9
19931355053.3
19921325162.6
1991956566.1
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.