2004 Chevrolet Astro
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Astro › 2004
These records cover every 2004 Chevrolet Astro. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
2 recalls name the 2004 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.
Owner complaints
14 complaints1 involved a crash1 involved a fire3 injuries
What owners report most
Latest complaints
- Vehicle speed control
Once or twice per year when using cruise control, when I touch brake to deactivate cruise, it doesn't disengage. I then have to stand on brake with all my effort to stop van and pull over to put in park. Engine continues racing til I turn key off. Then everything ok til next time maybe months…
Once or twice per year when using cruise control, when I touch brake to deactivate cruise, it doesn't disengage. I then have to stand on brake with all my effort to stop van and pull over to put in park. Engine continues racing til I turn key off. Then everything ok til next time maybe months later. Switck on brake petal IS ok. Once in the winter, cruise control pushed me into an intersection. Luckily other traffic realized I couldn't stop. No codes show up to identify cause. Been doing this 4 or 5 years intermittently. Even tho this van IS 16 years old, it only 6HAS 90000 miles on it. I try not to drive it much because of this problem. My best guess it's mechanical or computer problem but since it happens so seldom hard to diagnose.i have another astro 5 yr older with 230000 on it and cruise works like it should. I have no more information.
- Service brakes
Antilock braking system warning lights and brake light came on when I was entering the freeway. the lights continue to come on whenever I am driving. I had it checked at corning chevrolet and was told the part alone was $900 plus labor to replace it. the brakes work, but not the antilock system installed by the manufacturer.
- Service brakes
We live in the country with gravel roads. all of our chevrolet vehicles have had brake lines rot out. our ford and dodge vehicles have not. the chevrolet astro vans we have exhibit a propensity for the brake line rotting out over the gas tank as well as the brake lines over the front frame…
We live in the country with gravel roads. all of our chevrolet vehicles have had brake lines rot out. our ford and dodge vehicles have not. the chevrolet astro vans we have exhibit a propensity for the brake line rotting out over the gas tank as well as the brake lines over the front frame members. the brake lines on 20 year old ford vehicles look as good as new under the same conditions. my 1994 chevrolet k-3500 pickup has blown brakes lines due to rot along with the back part of the frame that rusted out. I just read where you have advised washing the underside of chevrolet vehicles several times a year. well the lines rotting out on top of the gas tank and the front frame rails will not get washed. whoever made the "wash it" decision evidently does not drive older chevrolets. if there was no problem then why did chevrolet evidently change their lines? or maybe they did not and the newer ones just have not started rotting out yet. why do ford brake lines, exhaust systems, frames, and bodies not rust like gm. someone IS hiding something. the chevrolet brake line are definitely a safety hazard due to rusting thru. *tr
- Electrical system › Starter assembly · Engine · Fuel system, gasoline › Delivery › Fuel pump
TL* the contact owns a 2004 chevrolet astro. The contact stated that the vehicle failed to start until after three attempts. The contact shifted into drive and then the vehicle lost all power. The contact pumped the accelerator pedal, waited ten minutes and the vehicle resumed its normal…
TL* the contact owns a 2004 chevrolet astro. The contact stated that the vehicle failed to start until after three attempts. The contact shifted into drive and then the vehicle lost all power. The contact pumped the accelerator pedal, waited ten minutes and the vehicle resumed its normal operation. the failure occurred on a regular basis. The manufacturer was not notified of the failure. The dealer diagnosed the failure and stated that the fuel pump needed to be replaced. The dealer assured the contact that after paying for the repair, the failure would be resolved. The fuel pump, starter, motor mounts, and generator were all replaced; however, the failure recurred. The failure mileage was 133,000. The current mileage was 134,249.
- Service brakes, hydraulic
It started with my ABS brake light coming on and staying on. Then I started to encounter anti lock pulsations when I slowed down and coming to a stop, some times I couldn't even stop when & where I wanted. Braking distance started being longer. Then some time later I felt as though someone stuck…
It started with my ABS brake light coming on and staying on. Then I started to encounter anti lock pulsations when I slowed down and coming to a stop, some times I couldn't even stop when & where I wanted. Braking distance started being longer. Then some time later I felt as though someone stuck a brick under my brake pedal because no matter how hard I press, I guarantee you, I couldn't stop. Thank god no one was in front of me as I cruised on though the stop light! I was told that my ABS sensors were slowly malfunctioning most likely due to corrosion, a proven design defect. Then my ABS module will get shorted, and there IS no fail/safe when it goes. I was told that when the module fails, hang on because I will crash. this scares me to death and I wont let anybody drive my van in case this happens when they are driving. Also when we want to take a trip I don't want to take my van because I'm afraid 6 to 8 people could get hurt and it would be on me. Every reason I bought this AWD van IS completely out the window. I cant sell it because of the brake problem. I'm stuck with a van that I cant use. I'm writing this because when I went to get the ABS serviced I find out that I could write a complaint about the problem ( I didn't even know you could do that ) because something about a communication problem to the ABS module since 1999. And that they recalled the chevy trucks that had the same problem years ago. I would think you would fix the vans before the trucks, because trucks don't carry a lot of people! They carry wood. when ever I drive this van now, I consider it a russian roulette. I cant afford the 2200.that was estimated to fix it. I have always believed in chevy, but I cant believe that I drive afraid every day. I cant believe that chevy knows about this problem. *tr
- Service brakes, hydraulic
I have an '04 chevy astro van with ~ 88K miles. it IS serviced every 3,000 miles. recently, my brakes failed. the cause was a worn brake line near the left front wheel. it had rubbed a hole it the line and I lost all the brake fluid. *tr
- Suspension
As I was driving over some railroad tracks both of my front torsion bars failed and broke. had I been traveling on the interstate, it could have been fatal. from my online research, this same failure has happend to thousands of owners and no recall was done. gm even redesigned the torsion bars because of the known design flaws and it will cost well over $1,000 to repair. *tr
- Parking brake
1. I parked my wife's van at the neighbor's house because guests were about to arrive. their driveway IS on a slight incline so I engaged the emergency brake. 2. it occurred just once with the pedal going completely to the floor. 3. after contacting gm and being denied compensation due to no…
1. I parked my wife's van at the neighbor's house because guests were about to arrive. their driveway IS on a slight incline so I engaged the emergency brake. 2. it occurred just once with the pedal going completely to the floor. 3. after contacting gm and being denied compensation due to no recall and the age of the vehicle I purchased and replaced the broken driver side emergency brake cable myself. I believe the cause was a design flaw. I have the old part if needed for examination. the cable was completely severed due to a crack in the outer sheath allowing moisture to enter and to deteriorate the cable. the crack occurred at a severe bend where a bracket secured the cable to the frame of the vehicle. *Tr
- Electrical system · Service brakes, hydraulic
When my wife returned to our 2004 chevrolet astro van, the vehicle seemed to have a dead battery. The car would not turn over or fire the ignition. After having the battery and starter checked, we were told the battery was drained and they were able to charge the battery. The starter checked good.…
When my wife returned to our 2004 chevrolet astro van, the vehicle seemed to have a dead battery. The car would not turn over or fire the ignition. After having the battery and starter checked, we were told the battery was drained and they were able to charge the battery. The starter checked good. The car seemed to have a "dead short" when trying to start and/or boost. after replacing all components, the van started, however, when I put my foot on the brakes, there was no brake pressure on the pedal. It appeared that we were losing brake fluid under the vehicle from a ruptured line. We towed the car home to inspect and replace the brake line. upon inspection, we found electrical arcing where the brake line had grounded on the vehicle frame causing a hole to rupture in the brake line just rear of the electrical unit. what we determined caused the problem was a hot wire that ran between the battery and starter was rubbing on the suspension links on the passenger side of the vehicle. It rubbed through the electrical sheath and caused contact between the frame and the electrical charging system if the vehicle. After contacting gm/chevrolet support, they were "sorry" about the issue and felt the issue was due to a wire clamp that "must be missing." we have temporarily repaired the issue, however, there were no factory wire clamps that were missing. This IS a design flaw from chevrolet on this vehicle that has been documented on the internet in various places. Had my wife been driving 55mph, she would have had no brakes due to the issue. Chevrolet simply said the vehicle was a 2004 and they would not take action on a vehicle "that old". Several of the vehicles electrical systems have been disrupted that are associated with the braking system such as door locks, daytime running lights, etc... we want the public warned about this issue so no lives are lost. we have temporarily repaired the issue, however, the original cable and ties are still in place. *Tr
- Air bags › Frontal
My wife was driving a 2004 chevy astro van approx. 35-40 mph on a two-way street. Another driver from the opposite direction cut across into her lane and had a head-on collision. She suffered a broken wrist & bruised ribs. She had three of our children in their seats. They were shaken and had…
My wife was driving a 2004 chevy astro van approx. 35-40 mph on a two-way street. Another driver from the opposite direction cut across into her lane and had a head-on collision. She suffered a broken wrist & bruised ribs. She had three of our children in their seats. They were shaken and had seatbelt bruises. The van was not drivable and was towed away. the police & the tow driver reported that the airbags did not deploy. We have some expectation that the airbags would have secondary role to minimize injuries. My compliant that the hard collision was sufficient to deploy safety equipment but did not work as designed. Was there a recall for airbag failures for this model of vehicle? *tr
- Service brakes, hydraulic › Antilock/traction control/electronic limited slip
TL*- whenever the contact drove the 2004 chevrolet astro van with 46,000 failure miles at any rate of speed the antilock brakes engaged on dry pavement. the contact stated that this should not be happening. the vehicle had not been repaired. The current mileage was 49,000.*ak update 04/30/07 *tr
- Latches/locks/linkages › Doors › Latch
Dt*: the contact stated the rear dutch door on the vehicle became stuck on 2 different occasions, and was not able to be opened from the inside. the vehicle was taken to a service dealer who determined that the latch rod retainer clip for the door had detached, and the rod had disconnected. the clip was replaced and the rod was reattached.*ak
- Vehicle speed control › Cruise control
Dt: without warning the cruise control will shut off when the consumer hits a bump. The consumer doesn't know when it's going to happen. the dealer was unwilling to troubleshoot, because the manufacturer will not reimburse them for the cost. The manufacturer will not pay to have test run on car. The consumer does not feel it's his place to pay. *jb
- Visibility › Glass, side/rear
Rear driver side window exploded and the glass completely shattered, without being struck with an object. Vehicle was parked and turned off when this occurred. Dealership was contacted. No injuries were sustained because the seat was not occupied at the time of the incident.*ak
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.
- 11007208This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
- 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.
- 11000576This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 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
- 10245395This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
- 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.
- 10244214This informational bulletin provides information for the IPC odometer programming method quick reference guide.
- 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.
Every Chevrolet Astro model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.