Total Complaints
46 filings
CHEVROLET VAN · model year
46 NHTSA complaints, 4 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1996CHEVROLETVAN carries 46 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 4 crashes, 1 fire, 0 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 VAN is service brakes, hydraulic:antilock/traction control/electronic limited slip with 11 filings, followed by service brakes, hydraulic:foundation components:disc (3) and suspension:front:springs:torsion bar (3). 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 VAN, 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
46 filings
Crashes Reported
4 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 | 11 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC | 3 |
| SUSPENSION:FRONT:SPRINGS:TORSION BAR | 3 |
| ENGINE AND ENGINE COOLING:ENGINE:GASOLINE | 2 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 2 |
| FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP | 2 |
| SEAT BELTS:FRONT:ANCHORAGE | 1 |
| SEATS | 1 |
| SEATS:FRONT ASSEMBLY:HEAD RESTRAINT | 1 |
| EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC. | 1 |
| VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR | 1 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM | 1 |
| STEERING:HYDRAULIC POWER ASSIST SYSTEM | 1 |
| WHEELS:LUGS/NUTS/BOLTS/STUDS | 1 |
| ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH | 1 |
DT*: THE CONTACT STATED THE HARNESS THAT CONNECTS THE POWER TO THE TOP OF THE FUEL PUMP FAILED CAUSING ARCING THAT BURNS THE CONNECTOR. THIS MELTED THE PLASTIC ON THE INSIDE OF THE FUEL TANK AND THE VEHICLE STALLED. THE DEALERSHIP DETERMINED THE FUEL PUMP NEEDED TO BE REPLACED. TWO FUEL PUMPS WERE INSTALLED. AFTER THE SECOND FUEL PUMP WAS INSTALLED, THE DEALERSHIP DETERMINED THE CONNECTOR WAS BAD.
Mileage: 150,000
DT*: THE CONTACT STATED THAT THERE WAS GASOLINE SPILLING OUT OF THE FILLER NECK OF THE REAR FUEL TANK. THE VEHICLE WAS TAKEN TO A SERVICE DEALER, WHERE THE DEALER DETERMINED THAT THE PUMP IN THE REAR TANK FAILED. THE VEHICLE WAS NOT REPAIRED AT THAT TIME. THERE IS A NHTSA RECALL # 93V125000, PERTAINING TO THE FUEL TANK ASSEMBLY HOWEVER THE VIN WAS NOT INCLUDED IN THE RECALL.
Mileage: 150,000
DT: THE CONSUMER STATED THE HEADLIGHTS WERE BLINDING TO OTHER VEHICLES. THE HEADLIGHTS HAVE BEEN ADJUSTED NUMEROUS TIMES AND HAVE BEEN REPLACED ABOUT 10 TIMES.*AK
2 MULTI PORT INJ 1INTAKE MANIFOLD GASKET
Mileage: 116,281
2 MULTI PORT INJ 1INTAKE MANIFOLD GASKET
Mileage: 116,281
1996 CHEVROLET ASTRO VAN. WE WERE DRIVING DOWN A BUSY INTERSTATE 65 MILES AN HOUR WHEN THE FRONT PASSENGER SIDE COLLAPSED. LUCKILY MY HUSBAND GOT THE VEHICLE UNDER CONTROL AND OFF OF THE ROAD, MY ENTIRE FAMILY COULD HAVE BEEN KILLED. WE LEARNED THAT IT WAS A TORSION BAR AND THAT THIS IS A COMMON DESIGN PROBLEM AND THAT THE DESIGN WAS CHANGED IN 1997. THEREFORE WE HAD TO REPLACE BOTH SIDES AT A COST OF OVER 1,000 DOLLARS. IT IS STILL MAKING A NOISE AND I DON'T FEEL IT IS RELIABLE. *NLM
Mileage: 77,980
WHILE PARKED WITH NO KEYS IN THE IGNITION CHILD ACCIDENTLY PUT VEHICLE INTO GEAR WITHOUT APPLYING BRAKES VEEHICLE ROLLED FORWARD, AND HIT A CEMENT BEAM, INJURING PARENT WHO WAS TRYING TO STOP THE VEHICLE. DEALER CONTACTED. *AK
HEARD A NOISE, FELT THE FRONT OF THE VEHICLE FALL DOWN ON THE FRONT PASSENGER TIRE, HEARD TIRE RUBBING, STOPPED VEHICLE, GOT OUT TO INSPECT. FENDER PARTS RUBBED ON TIRE, COULD NOT TURN WHEEL OR DRIVE , HAD TO HAVE VEHICLE TOWED TO REPAIR SHOP. REPLACE TORSION BAR AND RELATED PARTS.
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
PRIOR TO COMPLETE BRAKE FAILURE ON JULY 29, 2001, THERE IS MINIMUM OF NINE DOCUMENTED SERVICE REPORTS WITH THE DEALER FOR BRAKE PROBLEMS BEGINNING IN MAY OF 1997. TO DATE, THIS PROBLEM STILL EXISTS. THERE IS SEVERE PULLING TO THE RIGHT AND WHEEL VIBRATION UPON QUICK OR HEAVY APPLIANCE OF BRAKES. THE REAR BRAKES DO NOT WORK AND HAVE NOT WORKED PROPERLY FROM THE BEGINNING; THUS, THE FRONT BRAKES MUST HANDLE THE LOAD. THE FRONT BRAKE LINING MUST BE REPLACE EVERY SIX MONTHS. THE BACK BRAKE LINING HAS BEEN REPLACED ONLY ONCE. THE DEALER INDICATED THE RECENT BRAKE FAILURE WAS A RESULT OF THE ROTARS RUSTING AND SPLITTING IN HALF (A FIRST THEY SAY). THIS OCCURRED ONLY THREE MONTHS AFTER HAVING THIS VEHICLE INTO THE DEALER TO CHECK THE BRAKES AGAIN! THE REAR DRIVE SHAFT WAS REPLACED IN NOV. OF 1997, THE CATALYTIC CONVERTER HAD TO BE REPLACED IN FEB. 2000, THE IDLER ARMS (WHICH CAUSED PREMATURE WEAR OF TIRES) HAD TO BE REPLACED IN APRIL OF 2000 AND CONTROL ARM BUSHINGS WERE REPLACED I
I HAVE A PREVIOUS REPORT ON THIS VEHICLE BACK IN APRIL OF 2000. THIS VAN WOULD NOT STOP WHEN I WAS GOING DOWN A HILL AND I WENT INTO A HOUSE. THEY FOUND NOTHING WRONG, WHICH I NEVER COULD BELIEVE. EVER SINCE THIS INCIDENT THE BRAKES NEVER FELT THE SAME. I HAVE RETURNED THIS VAN TO DEALERSHIP SEVERAL TIMES AND THEY COULD NEVER FIND ANYTHING WRONG. I TRANSPORT MY DAUGHTER IN THIS WHO IS IN A WHEEL CHAIR. TWO WEEKS AGO I BROUGHT THIS VAN IN AGAIN TO BE SERVICED AND THEY SAID SOMETHING TO DO WITH THE SENSOR, CLAIMED THEY FIXED IT BUT MY V AN AGAIN DID NOT STOP ON MY 1ST ATTEMPT OF APPLYING MY BRAKE. THE ANTI-LOCKE LIGHT KEEPS GOING ON AND OFF. I HAVE NOTICED WHEN LIGHT IS ON THE BRAKES WORK O.K., WHEN LIGHT IS OFF THE BRAKES MALFUNCTION. I DO NOT FEEL SAFE FOR MYSELF BUT MOST OF ALL MY FAMILY. IT IS IN THE DEALERSHIP TODAY AGAIN 4/15/01. *AK
THIS IS JUST FOR YOUR RECORDS THIS VEICHLE HAS A STOPPING PROBLEM ABOVE 40 MPH THE HARDER YOU PRESS BRAKES THE STOPPING DOES NOT INCREASE I AM FAMLLAR WITH ANTI LOCK BREAKS THIS IS NOT THAT SYSTEM CAUSEING THIS NON STOPPING OTHER VAN OWNERS LIKE MY SELF HAVE NOTICE THIS PROBLEM ITS ALMOST LIKE THERE IS NOT ENOUGH BREAK TO STOP ANTI BREAK WORKS FINE WHEN FORCED TO FLOOR BUT NORMAL STOPPING IS VERY WEAK .*AK
I AM DISAPOINTED THAT ALL NEWER CARS ON THE ROAD TODAY ONLY COME WITH PAINTED BUMPERS.BUMPERS THAT ARE PAINTED ARE LIKE HAVING NO BUMPER AT ALL WHEN IT COMES TO MINOR COLLISIONS. BUMPERS, I BELIEVE, SHOULD BE PROTECTION FOR THE PAINTED AREAS AS WELL AS THE LIGHTS, GRILL ETC. I WOULD LIKE TO SEE A MANDATE THAT BUMPERS NOT BE PAINTED. SEEMS LIKE COMMON SENSE TO NOT DRIVE AROUND WITH THE MOST LIKELY AREAS TO BE DAMAGED AS PAINTED OR OTHERWISE DELICATE.PLEASE CONSIDER THIS IN YOUR EVALUATIONS AS IT WILL GREATLY REDUCE CONSUMER EXPENCES INVOLVING ACCIDENTS THAT ARE NOT COVERED BY AUTO INSURANCE ( ACCIDENTS UNDER 500.00). THANK YOU.*AK
2 BUCKET SEATS LOCATED IN MIDDLE OF VAN ARE LOOSE AND WOBBLY. CONSUMER FEELS THIS IS UNSAFE. *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.