CHEVROLET ASTRO · model year

1996 CHEVROLET ASTRO

345 NHTSA complaints, 22 crash reports for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 1996CHEVROLETASTRO carries 345 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 22 crashes, 1 fire, 18 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 1996 ASTRO is suspension:front:springs:torsion bar with 38 filings, followed by visibility:windshield wiper/washer:motor (26) and service brakes, hydraulic:antilock/traction control/electronic limited slip (21). 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 1996 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.

345
Complaints
22
Crashes
1
Fires
18
Injuries
0
Deaths

Total Complaints

345 filings

Crashes Reported

22 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

Above median complaint volume — review patterns below.

Complaints by Component

ComponentCount
SUSPENSION:FRONT:SPRINGS:TORSION BAR38
VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR26
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP21
VISIBILITY:WINDSHIELD WIPER/WASHER21
AIR BAGS:FRONTAL13
POWER TRAIN:AUTOMATIC TRANSMISSION12
STRUCTURE:BODY:DOOR11
SUSPENSION:FRONT9
EQUIPMENT:APPLIANCE:AIR CONDITIONER8
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP7
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS6
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS6
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS6
UNKNOWN OR OTHER5
VEHICLE SPEED CONTROL5

Recent Complaints

20151226SERVICE BRAKES

PIN HOLES IN STEEL BRAKE LINES CAUSING COMPLETE BRAKE FAILURE. FORTUNATELY VEHICLE WAS SITTING WHEN BRAKE PETAL WAS APPLIED FOR STARTING. WHEN PRESSING BRAKE TO START VEHICLE, PETAL WENT COMPLETELY TO FLOOR. WHEN CHECKING UNDER VEHICLE TO ANALYZE PROBLEM, PIN HOLES LEAKS WERE OBSERVED IN VARIOUS PLACES FROM FRONT TO REAR IN STEEL LINES. I FEAR WHAT MAY HAVE HAPPENED HAD THE VEHICLE BEEN IN MOTION, AROUND PEDESTRIANS, AND/OR, ON THE ROAD.

Mileage: 120,227

20130902SERVICE BRAKES

I JUST GOT HOME & WAS BACKING AROUND TO WHERE I PARK WHEN THE BRAKE PEDAL STARTED VIBRATING. I DID MANAGE TO PARK. THE NEXT DAY THE VIBRATING STOPPED WHEN A GRATING NOISE WAS MADE. SUDDENLY THE BRAKE PEDAL CAME WAY UP. IT DOES HAVE SOME BRAKES BUT THEY ARE HARD TO DEPRESS. SUDDENLY MY POWER STEERING IS GONE. THERE WAS NO INDICATION OF PROBLEMS WITH EITHER BEFOREHAND. THIS VAN JUST PASSED INSPECTION IN MID-AUGUST, AND HAS ALWAYS BEEN TAKEN CARE OF. *JS

Mileage: 235,059

20130902STEERING

I JUST GOT HOME & WAS BACKING AROUND TO WHERE I PARK WHEN THE BRAKE PEDAL STARTED VIBRATING. I DID MANAGE TO PARK. THE NEXT DAY THE VIBRATING STOPPED WHEN A GRATING NOISE WAS MADE. SUDDENLY THE BRAKE PEDAL CAME WAY UP. IT DOES HAVE SOME BRAKES BUT THEY ARE HARD TO DEPRESS. SUDDENLY MY POWER STEERING IS GONE. THERE WAS NO INDICATION OF PROBLEMS WITH EITHER BEFOREHAND. THIS VAN JUST PASSED INSPECTION IN MID-AUGUST, AND HAS ALWAYS BEEN TAKEN CARE OF. *JS

Mileage: 235,059

20100507SUSPENSION:FRONT

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

20080227POWER TRAIN:AUTOMATIC TRANSMISSION

1996 CHEVROLET ASTRO WITH TRANSMISSION FAILURE. CONSUMER BELIEVES THAT THE PART THAT FAILED WAS THE SUNSHELL. HE HEARD THAT IF THIS PART FAILS, THE REVERSE AND SOME FORWARD GEARS WILL BE LOST. *KB

20070625ELECTRICAL SYSTEM:IGNITION

TL*THE CONTACT OWNS A 1996 CHEVROLET ASTRO. WHILE DRIVING 55 MPH, THE VEHICLE SHUT OFF WITHOUT WARNING. THE CONTACT FOUND A RECALL NOTICE INSIDE THE VEHICLE FROM WHEN IT WAS PURCHASED. THE RECALL LETTER PERTAINS TO THE IGNITION COIL WIRE. THE PURCHASE DATE WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 180,000.

Mileage: 180,000

20070120ELECTRICAL SYSTEM

ELECTRICAL FAILURE. REPEATED IN A 1996 CHEVY ASTRO. LEADING TO STARTER ENGAGE WHILE ENGINE RUNNING. *NM

Mileage: 132,000

20050818ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH

DT: 1996 CHEVROLET ASTRO. THE VEHICLE BEGAN TO SMOKE ON AUGUST 11, 2005. THE SMOKE WAS COMING FROM THE DASHBOARD. THE VEHICLE WAS BEING DRIVEN WHEN THIS OCCURRED. THE CONSUMER STATED THE SWITCH OR THE PLUG FOR THE REAR AIR CONDITIONER BLOWER MELTED. ALSO, MELTED THE FIRST SIX INCHES OF THE WIRING HARNESS. THE VEHICLE IS STILL DRIVABLE. THE CONSUMER WAS ABLE TO PULL THE VEHICLE OVER AND TURN IT OFF. HE CHECKED TO MAKE SURE THERE WERE NO FLAMES. THIS PROBLEM HAS NOT YET BEEN REPAIRED. *AK

Mileage: 140,000

20050527SUSPENSION:FRONT:SPRINGS:TORSION BAR

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

Mileage: 71,000

20050227POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

I WAS DRIVING DOWN THE INTERSTATE AT 65 MILES PER HR. AND ALL OF A SUDDEN I SAW WHITE SMOKE COMING FROM THE BACK OF MY VAN, IT LOOKED LIKE THE VAN WAS ON FIRE, I LOST ALL POWER TO THE VAN, AND HAD NO PICK-UP OR SPEED. I HAD TO DIVERT THE VAN TO THE SHOULDER OF THE HIGHWAY. WHEN I LOOKED UNDER THE HOOD I FOUND THAT THE TRANSMISSION CABLE HAD COME UNATTACHED, AND I HAD TRANSMISSION FLUID ALL OVER THE GROUND. THERE WERE NO WARNING SIGNS WHATSOEVER. TRANSMISSION FLUID SPRAYED ALL THE WAY TO MY BACK WINDSHIELD OF THE VAN. *JB

Mileage: 110,000

20040809STRUCTURE:BODY:DOOR

WHILE DRIVING PASSENGER'S SIDE DOOR CAME OFF DUE TO DEFECTIVE PLASTIC. *AK

Mileage: 58,903

20040806SUSPENSION:FRONT:SPRINGS:TORSION BAR

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

Mileage: 80,222

20040616EQUIPMENT:APPLIANCE:AIR CONDITIONER

1)AC COMPRESSOR STOPPED WORKING 2)COMPRESSOR SEIZED UP, ENGINE STOPPED RUNNING, AND VEHICLE STOPPED ON HIGH TRAFFIC HIGHWAY 3)SORT BELTED SERPENTINE BELT . *AK

Mileage: 120,000

20040616ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

1)AC COMPRESSOR STOPPED WORKING 2)COMPRESSOR SEIZED UP, ENGINE STOPPED RUNNING, AND VEHICLE STOPPED ON HIGH TRAFFIC HIGHWAY 3)SORT BELTED SERPENTINE BELT . *AK

Mileage: 120,000

20040426FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

CONSUMER STATED THAT THE FUEL GAUGE DID NOT WORK. FUEL GAUGE SHOWED FULL, HALF FULL OR EMPTY. CONSUMER'S SISTER RECEIVED A RECALL CONCERNING FUEL GAUGE FAILURE, BUT HE HAD NOT RECEIVED A RECALL NOTICE. ALSO, CONSUMER'S WIFE RAN OUT OF FUEL BECAUSE OF FUEL GAUGE INACCURATE READING OF THE AMOUNT OF FUEL IN THE GAS TANK. IT WOULD COST OVER $500.00 TO HAVE REPAIRS DONE IF IT WAS NOT ON RECALL.*AK

20040422SUSPENSION

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.

Mileage: 92,000

20040422UNKNOWN OR OTHER

Mileage: 65,000

20040422ENGINE AND ENGINE COOLING

Mileage: 65,000

20040422SUSPENSION

Mileage: 65,000

20040422ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

Mileage: 65,000

Compare 1996CHEVROLETASTRO to Similar Vehicles

NHTSA Investigations 2 Open

View all investigations

Frequently Asked Questions

How many complaints does the 1996 CHEVROLET ASTRO have?
The 1996 CHEVROLET ASTRO has 345 NHTSA complaints, 22 crashes, 1 fires, 18 injuries, and 0 deaths reported.
What are the most common problems with the 1996 CHEVROLET ASTRO?
The most-complained component for the 1996 CHEVROLET ASTRO is SUSPENSION:FRONT:SPRINGS:TORSION BAR with 38 complaints. Other frequently reported areas include VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR and SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP.
Is the 1996 CHEVROLET ASTRO safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

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.