2002 Chevrolet Astro
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Astro › 2002
These records cover every 2002 Chevrolet Astro. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
3 recalls name the 2002 Chevrolet Astro. Newest first.
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, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative.
Risk and remedy
Risk
The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle IS braking and/or IS stopped and could lead to a vehicle crash.
Remedy
Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module free of charge. the repair would be used in vehicles in which the hazard slider button IS still movable. if a vehicle has a hazard slider button that IS not movable (frozen), the entire multifunction switch will be replaced. the recall began on april 13, 2005. owners may contact chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463.
Owner complaints
70 complaints7 involved a crash3 involved a fire4 injuries4 deaths
What owners report most
Latest complaints
- Vehicle speed control › Accelerator pedal · Vehicle speed control › Throttle
The contact owns a 2002 Chevrolet Astro. The contact stated that while driving at an undetermined speed, the accelerator throttle cable fractured in the stuck open position, causing the vehicle to accelerate to approximately 100 MPH independently. There were no warning lights illuminated. The local…
The contact owns a 2002 Chevrolet Astro. The contact stated that while driving at an undetermined speed, the accelerator throttle cable fractured in the stuck open position, causing the vehicle to accelerate to approximately 100 MPH independently. There were no warning lights illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and notified of the failure. The approximate failure mileage was 258,300.
- Tires
Goodyear viva 3 tires suffered stone punctures. tire size 215/75r15. bought two new ones 10/5/16 and two more new ones 3/7/17. this vehicle IS infrequently driven and only occasionally on county maintained gravel roads. Only drove 18300 miles before first stone puncture 9/27/20. second stone…
Goodyear viva 3 tires suffered stone punctures. tire size 215/75r15. bought two new ones 10/5/16 and two more new ones 3/7/17. this vehicle IS infrequently driven and only occasionally on county maintained gravel roads. Only drove 18300 miles before first stone puncture 9/27/20. second stone puncture occurred with only 12/17/20 with 15800 miles on that tire. third stone puncture occurred 1/17/20 with 16200 miles. dot number md36jk1r4116 for tires bought 13/7/17. Dot number md36jk1r1216 for tires bought 10/5/16.
- Air bags
While vehicle was being driven.the alert warning light for the air bags illuminated. I was afraid to drive the vehicle due too the air bag inflator might rupture or underinflate. In the event of a crash. An underinflated air bag may not properly protect the occupant. This scenario increases the risk of serious injury or death.
- Electrical system · Visibility/wiper
When raining widshield wipers dont work as directed, they do what they want. They stay on after shutting them off. And door locks lock and unlock repeatedly. Wipers also shut off in the middle of line of sifht intermittently. never works correctly
- Exterior lighting
TL* the contact owns a 2002 chevrolet astro. The contact stated that on several occasions, the brake lights and hazard lights failed. The contact stated that if the brake pedal was depressed and the hazard light switch was moved around the lights would function as intended. The vehicle was not…
TL* the contact owns a 2002 chevrolet astro. The contact stated that on several occasions, the brake lights and hazard lights failed. The contact stated that if the brake pedal was depressed and the hazard light switch was moved around the lights would function as intended. The vehicle was not taken to be diagnosed or repaired. The vehicle was not included in nhtsa campaign number: 05v099000 (exterior lighting). The manufacturer was notified of the failure. The failure mileage was not available. updated 07/13/16*lj the consumer stated the brake lights only worked, if the hazard light switch was forced to one side and held in place. Updated 07/13/16.*jb
- Service brakes
I got in my van to drive to a store and the brake pedal went right to the floor. There was brake fluid leaking from near the rear tire. The steel hard brake line running from the ABS unit to the rear axle IS rusted through and IS leaking. This was a sudden event. also the fuel lines look to be…
I got in my van to drive to a store and the brake pedal went right to the floor. There was brake fluid leaking from near the rear tire. The steel hard brake line running from the ABS unit to the rear axle IS rusted through and IS leaking. This was a sudden event. also the fuel lines look to be just as bad. I'm sure stainless steel lines would not have added much to the vehicles cost and would have prevented this hazard and expense. *tr
- Seat belts
TL* the contact owns a 2002 chevrolet astro. The contact stated that the driver's side seat belt webbing failed to lock and was able to be pulled from the housing. The failure recurred multiple times. The manufacturer was not made aware of the failure. The failure mileage was 325,000.
- Electrical system · Electronic stability control (esc) · Steering
I was driving and all of a sudden, the dash lights went out and the car died. I lost power steering, and I coasted to the side of the road. Come to find out the fuse box was hot and there was a few fuses that were blown. I replace the blown fuses and drove home. When I got home and turned off the…
I was driving and all of a sudden, the dash lights went out and the car died. I lost power steering, and I coasted to the side of the road. Come to find out the fuse box was hot and there was a few fuses that were blown. I replace the blown fuses and drove home. When I got home and turned off the van, I couldn't get it start I looked at the same fuse and they were blown again. The van now sits in the driveway till I figure this out. Because it IS too dangerous to drive. *tr
- Tires
TL* the contact owns a 2002 chevrolet astro equipped with gremax max 5000 tires (n/a), size 215/75r15 and the dot was jehkdvp2312. The contact stated that while traveling 40 mph, the front passenger side tire blew out. The manufacturer was not notified of the failure. The tire and vehicle failure mileage was 142,057.
- Electrical system · Service brakes
Vehicle lost all electrical power to every system that IS controlled by the ignition being turned on. Driver was in the process of making a u-turn around a curbing island in the divided traffic road when all electrical was interrupted while the steering wheel was turned all the way to the left.…
Vehicle lost all electrical power to every system that IS controlled by the ignition being turned on. Driver was in the process of making a u-turn around a curbing island in the divided traffic road when all electrical was interrupted while the steering wheel was turned all the way to the left. Condition caused steering to become difficult, brake pedal went clear to the floor, air conditioning and radio and headlights all went off. Condition was repeatable with exception of brake pedal, each time steering was turned to the left. Inspection under vehicle found that main power cable IS routed across front side of main frame motor mount member. There was a slight curve in the way the wire was routed and each time the steering was turned to the left, the inner tie rod end for the right wheel came in contact with the wire harness. After many miles, the protective cover and then the actual wire insulation was rubbed through. This caused a direct short to ground through the steering parts of all (switched while running) electrical components of the vehicle. Problem was corrected by taping the wire insulation, then taping the protective covering. I then had to fabricate a bracket to screw to the steel crumple member to hold the harness back from the steering linkage. *tr
- Electrical system · Equipment adaptive/mobility · Visibility › Defroster/defogger/hvac system › Windshield › Electrical heating element
Recently I took my van to a dealer because the knob on the a/c fan melted off it cost 600 dlrs in repairs the hvac knob had melted off also the connector and resistor had burned out . The entire wiring harness was melted together. No fuse blew to prevent his form happening we are not sure what…
Recently I took my van to a dealer because the knob on the a/c fan melted off it cost 600 dlrs in repairs the hvac knob had melted off also the connector and resistor had burned out . The entire wiring harness was melted together. No fuse blew to prevent his form happening we are not sure what caused this to occur. My concern IS that this could have caused a fire in the dash while I was driving resulting in severe injury accident or even death. Please contact me if there was a recall I missed or if there IS any information as to why this happened. Thank you for your time concern chevy owner. *tr
- Service brakes
ABS was activated at slow speeds causing a substantial drop in braking power. *Tr
- Electrical system
TL* the contact owns a 2002 chevrolet astro van. The contact stated when the vehicle was shifted into park she noticed there was smoke and fire behind the steering wheel. there was also a minor explosion. The fire department was notified and stated that an electrical wire started the fire. A…
TL* the contact owns a 2002 chevrolet astro van. The contact stated when the vehicle was shifted into park she noticed there was smoke and fire behind the steering wheel. there was also a minor explosion. The fire department was notified and stated that an electrical wire started the fire. A report was filed and the failure was not diagnosed nor towed from the contacts residence. The manufacturer was not notified. The failure and the current mileage was 170,000. updated 8/23/12
- Electrical system · Electronic stability control (esc) · Service brakes, hydraulic
ABS coming on at very low speeds on dry pavement (under 5mph/8kmh). it doesn't do it every time, but quite often at low speeds, like coming to a red light, stop sign or parking. of course, there IS no need for the ABS come on at such low speeds and especially not on dry pavement. *tr
- Service brakes, hydraulic · Service brakes, hydraulic › Antilock/traction control/electronic limited slip
TL* the contact owns a 2002 chevrolet astro. The contact stated that the front brake lines were rusted. The ABS unit was not working properly and the rear brakes had already failed. The vehicle was not inspected by the dealer but was repaired by the contact. The current mileage was 79,000 and the failure mileage was unknown.
- Service brakes, hydraulic › Antilock/traction control/electronic limited slip
TL* the contact owns a 2002 chevrolet astro van. When driving at low speeds the anti-lock braking system would activate without warning, increasing the vehicle's stopping distance. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 76,000. updated 5/12/10 *cn updated 06/18/10.*jb
- Service brakes, hydraulic · Steering
Tl*the contact owns a 2002 chevrolet astro van. The contact stated that while driving in reserve at approximately 5 mph, the brakes and the power steering malfunctioned. The vehicle was towed to a local mechanic. The mechanic could not remedy the problem. The contact stated that the vehicle was unsafe to drive. The failure mileage was 25,000.
- Vehicle speed control
Tl*the contact owns a 2002 chevrolet astro van. While driving 30 to 35 mph, the vehicle began accelerating on its own. The vehicle would not slow down by applying the brakes which forced the contact to shift gears into neutral and then into third gear. within a few minutes, the contact was able to…
Tl*the contact owns a 2002 chevrolet astro van. While driving 30 to 35 mph, the vehicle began accelerating on its own. The vehicle would not slow down by applying the brakes which forced the contact to shift gears into neutral and then into third gear. within a few minutes, the contact was able to slow down the vehicle engaging the brake pedal and shut the engine off. the contact was informed to engage the accelerator pedal to loosen the throttle; however, when he restarted the vehicle the rpm's increased rapidly. the police helped the contact push the vehicle onto the emergency lane. The vehicle was towed to the dealer. the dealer stated that the rapid acceleration was due to a frayed accelerator cable. the dealer replaced the accelerator cable and adjusted the idle and throttle plate. the vehicle IS driving normally. The contact requested the parts from the dealer who stated that they were not longer available. the contact IS concerned about the safety risk since a crash could have occurred. The failure mileage was 172,777.
- Exterior lighting
Hazard lights stop working and causes the trailer lights not to work( no left turn, right turn or brakes to trailer harness). Signals and brakes on van works okay but no hazards. *Tr
- Service brakes, hydraulic
TL. Contact owns a 2002 chevy astro van. current mileage was 97,000 and failure mileage were 50,000. Contact stated upon purchasing the vehicle from enterprise car rental the brakes have been bad. contact stated that the vehicle has been in the shop over 20 time most of the time for the brakes.…
TL. Contact owns a 2002 chevy astro van. current mileage was 97,000 and failure mileage were 50,000. Contact stated upon purchasing the vehicle from enterprise car rental the brakes have been bad. contact stated that the vehicle has been in the shop over 20 time most of the time for the brakes. contact has crash the due to the brakes on the vehicle. contact feels thatthe vehicle was a lemon upon purchase and does not feel this vehicle should be on the road. jo
- Steering · Structure › Frame and members
2002 chevy astro van idler arm pulled through the frame of the front right portion resulting in partial steering failure on february 1, 2009. Upon inspection by halleen chevrolet service department it was determined that not only had the front right idler arm broken through the frame but the front…
2002 chevy astro van idler arm pulled through the frame of the front right portion resulting in partial steering failure on february 1, 2009. Upon inspection by halleen chevrolet service department it was determined that not only had the front right idler arm broken through the frame but the front left idler arm was also in danger of breaking through. This would result in complete steering failure. The service department at the dealership determined that the vehicle needed a complete frame replacement. *Tr
- Structure › Body
Back door handle broke off the van cannot get in the back of the 2002 astro van. *Tr
- Service brakes, hydraulic
On march 26, 2008, I took my 2002 chevy astro van to be serviced. Mileage 93,829,i had no brakes. The master cylinder was determined to be the cause of the failure and was replaced. On april 12, 2008, once again I had no brakes, this time it resulted in me getting into and accident. I took the van…
On march 26, 2008, I took my 2002 chevy astro van to be serviced. Mileage 93,829,i had no brakes. The master cylinder was determined to be the cause of the failure and was replaced. On april 12, 2008, once again I had no brakes, this time it resulted in me getting into and accident. I took the van back to the same repair shop. When they put it on the lift they said the whole braking system was melted until the point of the hose bursting. He said he never saw anything like this in his 20 years of service. They did not want to touch it stating it was now a liability to them and directed me to chevy. Chevy concurred, four different people said they have never seen or have a clue at what caused this. They called in gm, who also never had seen this, but bounced the blame on a questionably installed master cylinder. Chevy said they can replace the whole braking system because they do not know what IS wrong, but since they do not know what caused this or why fuses didn't blow to prevent it, it could happen again. We hired our own car consultant to look at the van, he too has never seen or heard of anything like this. The heat and melted brake lines ran closer than 1/4 inch away from the gas tank. I do not want to take the risk of driving again with my children and loosing brakes or possibly igniting the gas tank. *Tr
- Exterior lighting › Brake lights › Switch
Tl*the contact owns a 2002 chevrolet astro. while the vehicle was undergoing a routine inspection, the contact was informed that his exterior lighting/brake light switches were inoperative. he called the dealer in reference to nhtsa campaign ID number 05v099000 (exterior lighting:brake…
Tl*the contact owns a 2002 chevrolet astro. while the vehicle was undergoing a routine inspection, the contact was informed that his exterior lighting/brake light switches were inoperative. he called the dealer in reference to nhtsa campaign ID number 05v099000 (exterior lighting:brake lights:switch). the dealer stated that his vin was not included in the recall although the failures were identical. the contact would be responsible for the repair costs. the manufacturer did not provide any assistance. the failure and current mileages were 70,000.
- Power train › Automatic transmission
Driving on 3 lane interstate at 70 mph when transmission failed(sun gear shell in 4l60e transmission). Early am with little traffic so was able to coast to shoulder safely. Towed to exit. Had to replace transmission very lucky that traffic was light as all drive power was lost. *tr
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Loss of brake lamp illumination
In its letter dated march 9, 2005, gm stated that it would conduct a safety recall to remedy a faulty multifunction switch in certain model year (my) 2001 and 2002 chevrolet astro and GMC safari vehicles; specifically, all my 2001 vehicles and early my 2002 vehicles built between march and august 2001.see nhtsa recall…
In its letter dated march 9, 2005, gm stated that it would conduct a safety recall to remedy a faulty multifunction switch in certain model year (my) 2001 and 2002 chevrolet astro and GMC safari vehicles; specifically, all my 2001 vehicles and early my 2002 vehicles built between march and august 2001.see nhtsa recall no. 05V-099 for details.the multifunction switch may develop an open circuit in the brake lamp or hazard lamp circuit resulting in inoperative brake lamps and hazard lamps.this IS due to the combined effects of the material and lubrication for the hazard switch contactor that result in increased resistance in the hazard switch and stuck hazard slider button in open (no contact) condition.dealers are to replace the hazard switch and apply special grease to the hazard switch contactor.if a vehicle has a stuck hazard slider button, dealers are to replace the entire multifunction switch.
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.
- 11009156This 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.
- 11007744This 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.
- 11007743This 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.
- 11006621Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11006421GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
- 11004761This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249590This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This 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.
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247552This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories.
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10245951Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- 10245950Canadian Customers Unable To Place Calls In The United States
- 10244274This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10244201This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
- 10242843The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
- 10242298This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10242262This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
- 10242252This technical bulletin provides information and a solution to a condition of Brake Pedal Moves or Self Applies at Full Turns.
- 10240793This 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.
- 10237671This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
- 10236164This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10235802This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
- 10235799This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10234141This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
- 10234110This service bulletin provides service information on new torque specification and installation procedure for ACDelco Spin-On Oil Filters.
- 10232811This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10232287This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
Every Chevrolet Astro model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.