1991 Chevrolet Astro: problems, recalls and reliability
6 recalls and 95 owner complaints on record; the weakest area is service brakes, hydraulic (44% of complaints).
Data updated weekly · latest recall May 2006
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 95 owner complaints filed with NHTSA for this exact model year.
“The door handles on both the passenger and driver side broke off. The sliding side door lock engaged before the door fully closed breaking the locking mechanism. I have seen several astro as well as safari vans with missing handles. I am having trouble finding replacement doors. *tr”Owner report · Structure · Jan 2006
“The driver's side seat belt retractor failed to retract on its own. The driver was able to contact the dealer for appointment. Please fill in additional information. *jb”Owner report · Seat Belts · Jan 2005
“Driver's side and passenger's side front and rear seat belt retractor failed to click in and hold. This problem occurred more than once and had not been resolved. Consumer contacted dealer on numerous occasions, but nothing was resolved. *ak *tc”Owner report · Seat Belts · Dec 2004
Show 7 more owner reports
“Consumer stated while driving pins in steering column sheared, causing steering to drop. Consumer had to pull to the side of the road and call a tow truck. Consumer had vehicle towed to his home, and repaired the problem himself. Also, door handles broke off, all almost at the same time, within a week apart. Consumer replaced them on his own. *ak”Owner report · Structure · Mar 2004
“Repeated total failure of brake system resulting in three separate rear end accidents over 13 year period. Original owner. When braking for sudden emaergency stop,after initial braking begins, brake petal goes down to floor and brakes completely release, resulting in no brake stoppage of vechicle and susequent rear ending of vehicle in front. Dealer denies sytem record of brake failure after second occurrance. When heard about recall, dealer says does not apply in canada, and not applicable to the 1991 model year.”Owner report · Service Brakes, Hydraulic · Oct 2003
“ABS brakes in front lock up when attempting to stop. Has been ongoing for numerous miles and now has been attributed to the control module for the kelsey hayes ABS system. Advised not to drive due to safety hazard. This apparently is a recall for several years, however, not 1991. I can not take my children in a vehicle that may lose its brakes because of an ABS control problem. *ak”Owner report · Service Brakes, Hydraulic · Nov 2000
“Both blowouts had the appearance (to a non-expert) of a tread separation problem. *ak (dot number: mkm3 trhr tiresize: p215/70r)”Owner report · Tires · Jul 2000
“Defect in design of all-wheel drive caused frame to rip and break in several places in left front making the vehicle un-repairable also broke right front drive shaft . Vehicle has been used for on-road use only ,”Owner report · Power Train · Jul 2000
“While making a sudden stop vehicle started to slow down, but then it released and kept going, consumer ran into another car. Took to dealer , and they could not duplicate the problem.*ak”Owner report · Service Brakes, Hydraulic · May 2000
“The ABS brakes were not operational after being applied. This happened after the ABS light came on. The brakes would lock up & then slide. This is an everyday problem. The brakes were replaced the first time at 87,000 miles. Now they have failed again. *ak”Owner report · Service Brakes, Hydraulic · Oct 1999
When filing, owners marked a crash in 12 of these complaints and injuries in 10 - self-reported to NHTSA, not verified accident statistics.
Recalls - 6 campaigns
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Remedy: REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL BETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEADS TO JOINT LOOSENESS, CAUSING BOLT FATIGUE AND EVENTUAL BOLT FAILURE.
Remedy: DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT FRAME "SOFT" JOINT AND REPLACE THE RECLINER BOLTS.
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, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
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 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.
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 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.
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.
THE SEAT BELTS FOR THE FRONT AND MID-SHIP SEATS DID NOT REST ON PELVIS AS REQUIRED BY FMVSS 209.
Remedy: RELOCATE SEAT BELT ANCHOR BOLTS TO ADJUST BELTS FOR SEAT LOCATIONS.
How other years compare
Check your exact Astro by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 1991 Chevrolet Astro reliable?
NHTSA has 95 owner complaints and 6 recall campaigns on record for the 1991 Chevrolet Astro. The most complained-about area is service brakes, hydraulic (44% of complaints).
At what mileage do 1991 Chevrolet Astro problems usually appear?
Half of the complaints that mention mileage were filed at 258,900 miles or less.
Does the 1991 Chevrolet Astro have open recalls?
6 recall campaigns have been issued, the latest concerning seat belts:front:anchorage. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.