Total Complaints
121 filings
CHEVROLET ASTRO · model year
121 NHTSA complaints, 15 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1991CHEVROLETASTRO carries 121 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 15 crashes, 5 fires, 11 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1991 ASTRO is service brakes, hydraulic:antilock/traction control/electronic limited slip with 40 filings, followed by structure:body:door (7) and electrical system:wiring:interior/under dash (5). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.
NHTSA currently has 57 investigation files overlapping the 1991 ASTRO, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
121 filings
Crashes Reported
15 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP | 40 |
| STRUCTURE:BODY:DOOR | 7 |
| ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH | 5 |
| SEAT BELTS:FRONT:RETRACTOR | 4 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT | 3 |
| SEAT BELTS:FRONT:WEBBING | 3 |
| POWER TRAIN:DRIVELINE:DRIVESHAFT | 3 |
| STEERING: STEERING WHEEL/HANDLE BAR | 3 |
| EQUIPMENT:APPLIANCE:AIR CONDITIONER | 3 |
| TIRES:TREAD/BELT | 3 |
| VISIBILITY:WINDSHIELD WIPER/WASHER | 2 |
| SEATS:FRONT ASSEMBLY:RECLINER | 2 |
| VEHICLE SPEED CONTROL | 2 |
| SEATS | 2 |
| LATCHES/LOCKS/LINKAGES:DOORS:LATCH | 2 |
BEGINNING ABOUT A YEAR AGO, HAVE HAD INTERMITTENT HARD PEDAL WHEN BRAKING. OCCURS RARELY, WITHOUT WARNING. NO ABS LIGHT SEEN BUT SUSPECT POSSIBLE ABS MALFUNCTION. PEDAL DOES NOT PULSATE BUT A FAINT GROWLING, GRINDING, OR BUZZING NOISE IS HEARD. MAY BE ABS MOTOR CYCLING. DURING FAILURE BRAKES ARE BARELY OPERATIVE. USUALLY RETURNS TO NORMAL OPERATION AFTER 2-3 PEDAL PRESSES. SOMETIMES PULLS SHARPLY LEFT, OCCASIONALLY RIGHT, ON BRAKE APPLICATION. THERE IS NO LOSS OF POWER STEERING. OCCURS MOST OFTEN AT FREEWAY SPEED BUT HAS ALSO OCCURRED AT SLOWER SPEEDS. HAS OCCURRED BOTH IN SUDDEN, HARD BRAKING AND IN VERY LIGHT USE. HAVE HAD ALL POWER COMPONENTS, ALL RUBBER HOSES, POWER STEERING PUMP, AND BOTH FRONT WHEEL BRAKE COMPONENTS PROFESSIONALLY REPLACED. VEHICLE HAS FRONT DISC/REAR DRUM AND HYDROBOOST. MECHANIC USUALLY CANNOT DUPLICATE THE PROBLEM BUT HAS DONE SO ONCE AND HAS NO EXPLANATION FOR IT. SEEKING TO LEARN POSSIBLE REASONS AND CURE.
Mileage: 258,900
THE DOOR HANDLES ON BOTH THE PASSENGER AND DRIVER SIDE BROKE OFF. THE SLIDING SIDE DOOR LOCK ENGAGED BEFORE THE DOOR FULLY CLOSED BREAKING THE LOCKING MECHANISM. I HAVE SEEN SEVERAL ASTRO AS WELL AS SAFARI VANS WITH MISSING HANDLES. I AM HAVING TROUBLE FINDING REPLACEMENT DOORS. *TR
THE DRIVER'S SIDE SEAT BELT RETRACTOR FAILED TO RETRACT ON ITS OWN. THE DRIVER WAS ABLE TO CONTACT THE DEALER FOR APPOINTMENT. PLEASE FILL IN ADDITIONAL INFORMATION. *JB
DRIVER'S SIDE AND PASSENGER'S SIDE FRONT AND REAR SEAT BELT RETRACTOR FAILED TO CLICK IN AND HOLD. THIS PROBLEM OCCURRED MORE THAN ONCE AND HAD NOT BEEN RESOLVED. CONSUMER CONTACTED DEALER ON NUMEROUS OCCASIONS, BUT NOTHING WAS RESOLVED. *AK *TC
PAINT PEELING OFF TRUCK ALL OVER
REPEATED TOTAL FAILURE OF BRAKE SYSTEM RESULTING IN THREE SEPARATE REAR END ACCIDENTS OVER 13 YEAR PERIOD. ORIGINAL OWNER. WHEN BRAKING FOR SUDDEN EMAERGENCY STOP,AFTER INITIAL BRAKING BEGINS, BRAKE PETAL GOES DOWN TO FLOOR AND BRAKES COMPLETELY RELEASE, RESULTING IN NO BRAKE STOPPAGE OF VECHICLE AND SUSEQUENT REAR ENDING OF VEHICLE IN FRONT. DEALER DENIES SYTEM RECORD OF BRAKE FAILURE AFTER SECOND OCCURRANCE. WHEN HEARD ABOUT RECALL, DEALER SAYS DOES NOT APPLY IN CANADA, AND NOT APPLICABLE TO THE 1991 MODEL YEAR.
CONSUMER STATED WHILE DRIVING PINS IN STEERING COLUMN SHEARED, CAUSING STEERING TO DROP. CONSUMER HAD TO PULL TO THE SIDE OF THE ROAD AND CALL A TOW TRUCK. CONSUMER HAD VEHICLE TOWED TO HIS HOME, AND REPAIRED THE PROBLEM HIMSELF. ALSO, DOOR HANDLES BROKE OFF, ALL ALMOST AT THE SAME TIME, WITHIN A WEEK APART. CONSUMER REPLACED THEM ON HIS OWN. *AK
CONSUMER STATED WHILE DRIVING PINS IN STEERING COLUMN SHEARED, CAUSING STEERING TO DROP. CONSUMER HAD TO PULL TO THE SIDE OF THE ROAD AND CALL A TOW TRUCK. CONSUMER HAD VEHICLE TOWED TO HIS HOME, AND REPAIRED THE PROBLEM HIMSELF. ALSO, DOOR HANDLES BROKE OFF, ALL ALMOST AT THE SAME TIME, WITHIN A WEEK APART. CONSUMER REPLACED THEM ON HIS OWN. *AK
THE BACK DOUBLE DOOR WILL NOT OPEN ANYMORE. I CAN NOT GET INTO THE VAN TO PLACE MY SONS WHEEL CHAIR INTO IT. THE SPACE IN THE REAR WAS THE REASON WHY I PURCHASED THE VEHICLE. THE SIDE DOOR WILL NO LONGER LOCK, AND THE INTERIOR LIGHT WILL NOT COME ON WHEN THE DOOR IS OPEN. *TS *NLM **DIMSII IVOQ ENTRY POSTED AFTER 12-12-02 CUT OVER TO ARTEMIS**770142
THE BACK DOUBLE DOOR WILL NOT OPEN ANYMORE. I CAN NOT GET INTO THE VAN TO PLACE MY SONS WHEEL CHAIR INTO IT. THE SPACE IN THE REAR WAS THE REASON WHY I PURCHASED THE VEHICLE. THE SIDE DOOR WILL NO LONGER LOCK, AND THE INTERIOR LIGHT WILL NOT COME ON WHEN THE DOOR IS OPEN. *TS *NLM **DIMSII IVOQ ENTRY POSTED AFTER 12-12-02 CUT OVER TO ARTEMIS**770142
WHILE TRAVELING AND WITHOUT ANY INDICATION TRANSFER CASE HAD BROKEN AWAY FROM FRAME OF VEHICLE . PLEASE PROVIDE FURTHER INFORMATION.*AK
BOTH BLOWOUTS HAD THE APPEARANCE (TO A NON-EXPERT) OF A TREAD SEPARATION PROBLEM. *AK (DOT NUMBER: MKM3 TRHR TIRESIZE: P215/70R)
ABS BRAKES IN FRONT LOCK UP WHEN ATTEMPTING TO STOP. HAS BEEN ONGOING FOR NUMEROUS MILES AND NOW HAS BEEN ATTRIBUTED TO THE CONTROL MODULE FOR THE KELSEY HAYES ABS SYSTEM. ADVISED NOT TO DRIVE DUE TO SAFETY HAZARD. THIS APPARENTLY IS A RECALL FOR SEVERAL YEARS, HOWEVER, NOT 1991. I CAN NOT TAKE MY CHILDREN IN A VEHICLE THAT MAY LOSE ITS BRAKES BECAUSE OF AN ABS CONTROL PROBLEM. *AK
WHILE IN A LOW SPEED ACCIDENT SHOULDER SEAT BELT DID NOT RETRACT, CAUSING CONSUMER TO HIT STEERING WHEEL. *AK
FIRESTONE RADIAL ATX TIRES(P215 75 R15)EXPERIENCED TREAD SEPARATION. *SLC
THIS ASTROVAN SHOWS SEVERE RUSTOUT OF ALL UNDERBODY COMPONENTS, PARTICULARLY STEEL BRAKE LINES, CALIPERS, DRUMS, ROTORS, ETC. SUSPENSION COMPONENTS ALSO HAVE RUSTED TO THE POINT WHERE THEY INFLUENCE VEHICLE SAFETY. DEALER ASSERTS THAT THIS IS DUE TO IMPROPER STORAGE OR SUBMERSION IN SALT WATER BUT VAN KEPT ON ASPHALT PAVEMENT AND NEVER USED IN WATER. CONDITION EXISTED FROM FIRST YEAR OF OWNERSHIP. INDEPENDENT MECHANICS ASSEERTED RUSTOUT IS CHARACTERISTIC OF ALL ASTROVANS THEY HAVE SEEN. TO DATE HAVE REPLACES OVER $2000 OF BRAKE, RUNNING GEAR AND EXHAUST COMPONENTS IN 45000 MILES. THIS IS CLEARLY NOT NORMAL WEAR AND TEAR.*AK
THIS ASTROVAN SHOWS SEVERE RUSTOUT OF ALL UNDERBODY COMPONENTS, PARTICULARLY STEEL BRAKE LINES, CALIPERS, DRUMS, ROTORS, ETC. SUSPENSION COMPONENTS ALSO HAVE RUSTED TO THE POINT WHERE THEY INFLUENCE VEHICLE SAFETY. DEALER ASSERTS THAT THIS IS DUE TO IMPROPER STORAGE OR SUBMERSION IN SALT WATER BUT VAN KEPT ON ASPHALT PAVEMENT AND NEVER USED IN WATER. CONDITION EXISTED FROM FIRST YEAR OF OWNERSHIP. INDEPENDENT MECHANICS ASSEERTED RUSTOUT IS CHARACTERISTIC OF ALL ASTROVANS THEY HAVE SEEN. TO DATE HAVE REPLACES OVER $2000 OF BRAKE, RUNNING GEAR AND EXHAUST COMPONENTS IN 45000 MILES. THIS IS CLEARLY NOT NORMAL WEAR AND TEAR.*AK
THIS ASTROVAN SHOWS SEVERE RUSTOUT OF ALL UNDERBODY COMPONENTS, PARTICULARLY STEEL BRAKE LINES, CALIPERS, DRUMS, ROTORS, ETC. SUSPENSION COMPONENTS ALSO HAVE RUSTED TO THE POINT WHERE THEY INFLUENCE VEHICLE SAFETY. DEALER ASSERTS THAT THIS IS DUE TO IMPROPER STORAGE OR SUBMERSION IN SALT WATER BUT VAN KEPT ON ASPHALT PAVEMENT AND NEVER USED IN WATER. CONDITION EXISTED FROM FIRST YEAR OF OWNERSHIP. INDEPENDENT MECHANICS ASSEERTED RUSTOUT IS CHARACTERISTIC OF ALL ASTROVANS THEY HAVE SEEN. TO DATE HAVE REPLACES OVER $2000 OF BRAKE, RUNNING GEAR AND EXHAUST COMPONENTS IN 45000 MILES. THIS IS CLEARLY NOT NORMAL WEAR AND TEAR.*AK
THIS ASTROVAN SHOWS SEVERE RUSTOUT OF ALL UNDERBODY COMPONENTS, PARTICULARLY STEEL BRAKE LINES, CALIPERS, DRUMS, ROTORS, ETC. SUSPENSION COMPONENTS ALSO HAVE RUSTED TO THE POINT WHERE THEY INFLUENCE VEHICLE SAFETY. DEALER ASSERTS THAT THIS IS DUE TO IMPROPER STORAGE OR SUBMERSION IN SALT WATER BUT VAN KEPT ON ASPHALT PAVEMENT AND NEVER USED IN WATER. CONDITION EXISTED FROM FIRST YEAR OF OWNERSHIP. INDEPENDENT MECHANICS ASSEERTED RUSTOUT IS CHARACTERISTIC OF ALL ASTROVANS THEY HAVE SEEN. TO DATE HAVE REPLACES OVER $2000 OF BRAKE, RUNNING GEAR AND EXHAUST COMPONENTS IN 45000 MILES. THIS IS CLEARLY NOT NORMAL WEAR AND TEAR.*AK
WHILE MAKING A SUDDEN STOP VEHICLE STARTED TO SLOW DOWN, BUT THEN IT RELEASED AND KEPT GOING, CONSUMER RAN INTO ANOTHER CAR. TOOK TO DEALER , AND THEY COULD NOT DUPLICATE THE PROBLEM.*AK
Loss of motive power due to engine failure
Loss of Motive Power due to the Battery Energy Control Module
Electric Vehicle Battery Fires
Outboard Front Seat Belt Anchor Cable Failure
Fuel Line Leak
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.