1996 Chevrolet Astro
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Astro › 1996
These records cover every 1996 Chevrolet Astro. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 1996 Chevrolet Astro. Newest first.
Certain ck motorsports combination headlights, clear corner, bumper, and side marker lights sold as replacement lamps for use on the 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.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy
Ck motorsport will notify owners and replace the noncompliant lamps free of charge. the recall began on july 1, 2006. owners may contact ck motorsport at 1-909-610-7211.
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…
Risk and remedy
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.
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).
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.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
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.
On certain minivans, pickup trucks, and sport utility vehicles with certain model-engine combinations, the windshield wiper motor may fail due to cracked solder joints on the controller circuit board. the windshield wipers could work intermittently or not at all.
Risk and remedy
Risk
If this were to occur during bad weather, driver visibility would be reduced, which could result in a crash.
Remedy
Dealers will replace the wiper motor circuit board and cover. owner notification began on june 19, 2003. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or oldsmobile at 1-800-442-6537.
Vehicle description: MINI vans. some of these vehicles fail to comply with requirements of fmvss no. 208, "occupant crash protection." the "fasten safety-belt" audible warning occasionally may not come on or may terminate in less than four seconds as required by the standard.
Risk and remedy
Risk
This does not meet the requirements of the standard.
Remedy
Dealers will install a new alarm module. owner notification began june 27, 2001. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782.
Vehicle description: MINI vans equipped with integrated dual child seats. some of these vehicles may be missing a seat belt retractor clutch spring and/or pawl spring in the child seat. if the clutch spring was missing, the seat belt would lock in the retracted position and could not be used. if the pawl spring was missing, the seat belt restraint…
Risk and remedy
Risk
These conditions could increase the occupant's risk of injury in the event of a vehicle crash.
Remedy
Dealers will inspect the seat belts on the child seats, and if necessary, replace the child seat.
The outboard safety belt webbing on the right-hand rear bucket seat can separate during a vehicle crash.
Risk and remedy
Risk
In the event of a crash, the vehicle occupant would not be properly restrained and personal injury could result.
Remedy
Dealers will install a protector on the rear seat cushion frame.
Owner complaints
263 complaints17 involved a crash1 involved a fire12 injuries
What owners report most
Latest complaints
- Service 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…
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.
- Service brakes · Steering
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…
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
- Suspension › 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…
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
- Power 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
- Electrical 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.
- Electrical system
Electrical failure. repeated in a 1996 chevy astro. leading to starter engage while engine running. *nm
- Electrical 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…
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
- Suspension › 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…
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
- Power 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…
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
- Structure › Body › Door
While driving passenger's side door came off due to defective plastic. *ak
- Suspension › 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…
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
- Engine and engine cooling › Engine › Gasoline › Belts and associated pulleys · Equipment › 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
- Fuel 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
- Suspension
I would like to report what I feel is/was a very serious safety defect with my 1996 chevrolet all wheel drive astro van [xxx]. recently while driving the right front suspension torsion bar snapped, collapsing the suspension, dropping the entire right side on top of the right front wheel and tire…
I would like to report what I feel is/was a very serious safety defect with my 1996 chevrolet all wheel drive astro van [xxx]. recently while driving the right front suspension torsion bar snapped, collapsing the suspension, dropping the entire right side on top of the right front wheel and tire pulling drastically to the right across 2 lanes of traffic. Fortunately traffic was light, and I was traveling at a slow speed -about 40 km/hr in a posted 50KM zone as I had just entered the 4-lane roadway. I managed to regain control of the van and steer it to the side of the right hand side of the road. I shudder at the thought if this had happened on the highway or freeway. The licensed journeyman mechanic that looked at the van indicated this was quite common on 90-96 all wheel drive vans stating that the torsion bar actually rusts or corrodes at almost the exact same spot (near the adjuster assembly) and eventually snaps completely breaking the torsion bar into 2 pieces! while he mentioned it was usually the driver's side (mine was passenger side) he indicated gm had recognized the problem and actually completely changed the design of both the torsion bar and the adjuster mechanism! however after contacting a couple of local gm dealers, they all told me was that this was not a product service bulletin related item or an official safety recall! yet they all had heard of it and just happened to have all of the parts in stock to the tune of $1000 (you have to replace both sides with the redesigned items). I found it surprising that they just happened to have 6 torsion bars and 6 adjusters in-stock; when I recently had to special order the rear door handle that had broken. I was told they only stock commonly replaced items at that time. the fact that it was redesigned tells me something. a component that IS subject to wear should have some sort of published inspection process, wear measurement procedure or even a regularly scheduled replacement interval. information redacted pursuant to the freedom of informati
- Engine and engine cooling · Engine and engine cooling › Exhaust system · Fuel system, gasoline · Suspension · Unknown or other
- Suspension
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.
- Engine and engine cooling › Cooling system › Hoses/lines/piping/fittings · Power train › Automatic transmission · Steering › Linkages › Tie rod assembly
The oil cooler lines leaked oil onto the engine which caused it to smoke. the oil cooler lines have been replaced three times within the last 30,000 miles. *nm there was noise in the front end due to a worn right front outer tie rod and when damp or cold out, a hard shift would be present when making turns. *scc
- Suspension › Front › Springs › Torsion bar
My wife went to move our 1996 chevrolet astro van and when she backed up the right front tire was rubbing on the wheel well. Upon further investigation it was determined that one of the torsion bars broke. *Ak when I called my local dealer I found the parts were readily available but I would have…
My wife went to move our 1996 chevrolet astro van and when she backed up the right front tire was rubbing on the wheel well. Upon further investigation it was determined that one of the torsion bars broke. *Ak when I called my local dealer I found the parts were readily available but I would have to replace both sides because they had been "updated". The parts alone were over $500.00. when I removed the old torsion bars I found out what had caused it to break, the receiver tube that the end of the bar went into had filled with dirt and road crude causing the bar to rust and eventully break. this occured four days before we were leaving on a 2500 mile trip. If this had occured when we were going down the interstate at 75mph or in the mountains while on vacation it could have been diasaterous. my last complaint IS that I was required to replace both torsion bars because the new one would not match the old. You should not have to replace something that IS not broken and if they do require you to do so the manufacturer IS admitting there IS a problem with the old design. I checked in your records and found that the astro and safari vans built from 1992-1996 had almost 200 cases of these torsion bars breaking and a complaint being filed. Who knows how many other ones have broken and gone unreported.the 1997 models did not seem to have a problem because they came out with the updated parts.
- Air bags › Frontal
While at a complete stop vehicle was rear ended at 50 mph . upon impact, vehicle was pushed forward, and rear ended the vehicle in front. none of the air bags deployed, and driver sustained back and neck injuries.*ak
- Visibility › Rear window wiper/washer › Motor
Request for reimbursement for repairs made to windshield wiper motor circuit board. *mr faulty windshield wiper motor circuit board cracked and caused them to fail. recall#03v159000 *scc *jb
- Suspension › Front › Springs › Torsion bar
Fracture of right side torsion bar caused body to drop onto wheel, immobilizing vehicle. Repairs cost $797.12 plus $40 towing and loss of use for three days.*ak
- Vehicle speed control › Accelerator pedal
The gas pedal became stuck when the vehicle was reverse or drive. the vehicle jerked forward and then accelerated. the pedal sticking was consistent and released after pressing harder on pedal several times. the vehicle had been taken vehicle to the dealership several times for sticking. The…
The gas pedal became stuck when the vehicle was reverse or drive. the vehicle jerked forward and then accelerated. the pedal sticking was consistent and released after pressing harder on pedal several times. the vehicle had been taken vehicle to the dealership several times for sticking. The mechanic indicated that it was repaired. vehicle not on recall. it was an ongoing problem since vehicle was bought new. Currently, dealership indicated warranty expired, and would not do repairs. *ak *scc *jb
- Visibility › Power window devices and controls
I have a 1996 chevrolet astro van. I've replaced the driver and passenger side power window motor's four times, each. Our company has 26 vehicles, all astro van's and all have the same problem. I just received a recall notice about the wiper motor on this vehicle. the power window motor…
I have a 1996 chevrolet astro van. I've replaced the driver and passenger side power window motor's four times, each. Our company has 26 vehicles, all astro van's and all have the same problem. I just received a recall notice about the wiper motor on this vehicle. the power window motor definitely IS more of a problem. I can't believe that there hasn't been a recall. in the winter, you'll being driving, lower the window and all of a sudden can't get it up. it's even more of a problem when it rains. please check into this. I first replaced the motor on both sides @ 19,000 mile, than 39,000 miles and so on. when I called gm to complain the customer service rep was stone cold; couldn't care less! if you check into this you'll see it's a majpor problem.*ak
- Suspension › Front › Springs › Torsion bar
Driver's side torsion bar broke. I've seen numerous complaints of this same failure on various web sites. Fortunately, my torsion bar broke while backing out of our driveway. This could have been a catastrophic failure had it occured while driving on the freeway.
- Seat belts › Front › Warning light/devices
Consumer had recall 01v123000 "audible warning" remedied on 6/13/03. a few days later he began experiencing problems with vehicle's electrical system. when the interior cabin light was turned on the radio would come on instead. also, when attempting to adjust power windows, the vehicle's alarm would engage. vehicle IS currently being checked by dealer.*ak
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Windshield wiper failure
As a result of this, and the precedinginvestigation, rq99-003, gm has expanded the population of safety recall 98v-150 (replacement of the windshield wiper control module) to include an additional 1.77 million vehicles.included are various 1994-1997 my M/L vans, s/t trucks and suvs, & c/k trucks and suvs.see attached technical report for details.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10232287This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
- 10208027This 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.
- 10171318This 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.
- 10170494This informational bulletin provides information for dealers/technicians on Procedures to Unlock Delco Radio with Theftlock.
- 10168979This Preliminary Information communication provides information to the technician on how to unlock radios that are Delco TheftLock. Technician will use the radio to get the scrambled code. Technician will need to contact the radio unlock center to retrieve the unlock code from the scrambled code. The PI update to version D is to advise the unlock procedure is temporarily unavailable. E version update is to add administrative details.
- 10166638This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
- 10165876This Preliminary Information communication provides information to the technician on how to unlock radios that are Delco TheftLock. Technician will use the radio to get the scrambled code. Technician will need to contact the radio unlock center to retrieve the unlock code from the scrambled code. The PI update to version D is to advise the unlock procedure is temporarily unavailable.
- 10157018This 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.
- 10154641This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
- 10141381This Preliminary Information communication provides information to the technician on how to unlock radios that are Delco Theft Lock. Technician will use the radio to get the scrambled code. Technician will need to contact the radio unlock center to retrieve the unlock code from the scrambled code.
- 10139019This preliminary informational bulletin provides information on High Oil Pressure on Startup After Engine Replacement Concern.
- 10138060This warranty administration bulletin provides policy information with the field action courtesy transportation policy.
- 10114947This Preliminary Information communication provides information to the technician on how to unlock radios that are Delco TheftLock. Technician will use the radio to get the scrambled code. Technician will need to contact the radio unlock center to retrieve the unlock code from the scrambled code.
- 10114924This Preliminary Information communication provides information to the technician on how to unlock radios that are Delco TheftLock. Technician will use the radio to get the scrambled code. Technician will need to contact the radio unlock center to retrieve the unlock code from the scrambled code.
- 10113443This 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.
- 10028790General motors: on all 1988-2009 full size chevrolet/gmc pickups, utilities and vans, the brake pedal will move down or self apply during full lock turns or near full lock turns. Chevrolet astro and GMC safari vans; hummer 2 are included. Updated 5/24/11.
- 10012145Boom type noise during engine warm up. This service bulletin replaces 000605001a.
- 10010375Service engine soon light and p0300 when towing, cruising uphill or on hard acceleration.
- 10007838Diagnostic information for intermittent transmission downshift, slip, busy/cycling tcc or noisy cooling fan.
- 10007811Intermittent battery light comes on, intermittent no crank.
- 10007717Engine coolant leak at intake gasket. * mj
- 10007458Part number 15042486 per bulletin 00-03-09-001a for the rear spring damper kit IS currently not available.
- 10007457Part number 15042486 leaf spring damper mentioned in technical service bulletin (tsb) 00-03-09-001a IS not available.
- 10007244Window regulator motor does not fit.
- 10005528Concerns with boom type noise during engine warm-up heard in the vehicle passenger compartment.
- 10004371Rattle noise in engine.
- 10004301Rattle noise in engine.
- 10002567Windshield wiper failure due to cracked boulder joints on the controller circuit board. This special policy covers the condition for a period of seven years or 70,000 miles, whichever occurs first from the date the vehicle was originally placed in service regardless of ownership or for these vehicles currently outside of this coverage until february 29, 2004.
- 10001125Special policy adjustment - windshield wiper motor failures.
- 10000749Antilock brake (ABS) activation at low speeds on various models including the 1995 and 1996 envoy.
- 10000062Antilock brake (ABS) activation at low speeds.
- 634999Diagnosis of cracked or broken transmission case. 2006 and prior cars and light duty trucks.
- 634576Some customers may comment that the right rear door handle on the cargo door breaks.
- 634273Subject regarding revised dtc p0340 camshaft position (cmp) sensor circuit diagnositc. Nlm
- 628070Some vehicles may exhibit an exhaust noise, rattle noise at 550 rpm.
- 623540Information regarding fasten seat belt warning audible signal parts availability. *Slc
- 623443This bulletin states that general motors has decided that certain vehicles fail to confirm to federal/canada motor vehicle safety standard 208, occupant crash protection, 208, occupant restrain system in frontal impact, and article 22-3, trias 49, seat belt warning device, sometimes on certain vehicles the seat belt audible signal may not come on or may terminate in less than four seconds. *Slc
- 623397Campaign parts bulletin regarding fasten seat belt warning audible signal.
- 620862Subject regarding fasten seat belt warning audible signal - parts information update.
Every Chevrolet Astro model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.