1991 Chevrolet Astro Problems

What owners report

Owners of this model year most often describe brake problems, particularly occasions when the pedal goes to the floor and braking power drops away during stops. Reports span many years of ownership and high mileage, with several describing repeat brake work and dealer visits where the problem could not be reproduced. Other recurring themes are broken door handles and hardware, melted wiring under the dash, and seat belts that do not hold or retract.

1. 1
   Brakes

   Brake pedal goes to the floor, braking power lost

   • 29 complaints (31%)
   • median 258,900 mi at 29.1 yrs old (1 states mileage, few)
   • 5 mention a crash, fire or injury
   • filed 1995–2019

   Complaints describe the brake pedal sinking to the floor during normal or emergency stops, with the vehicle continuing to roll or taking much longer to stop. Many owners say the condition comes and goes, and that pumping the pedal a few times restores normal braking. Several report that the antilock brake warning light came on and that dealers replaced the ABS unit, the master cylinder, or the brake pump, while others say the dealer could not duplicate the problem. Some filers state they were told a brake recall did not apply to this model year. Reported across a wide range of mileage and ownership periods, often during sudden or panic stops and sometimes on downgrades.

   1 related service bulletin

   What to check: Ask whether the ABS unit, master cylinder, or brake pump has been replaced and whether any brake-related service bulletin has been applied. Have a mechanic inspect the brake hydraulics and ABS function, and note that a soft or sinking pedal on a test drive should be taken seriously.

   2 excerpts from owner complaints in NHTSA records

   “After a stop, vehicle off, I drove for 1/2 mile to a stop sign, road completely dry, no sand, dirt, etc, 55 degrees sunny, and brakes worked nornal as I slowed from about 20,,then all of a sudden complete loss of brakes,,and pedal went to floor,,and I pushed harder in panic,,went thru stop sign,,and took foot off brakes, and pumped pedal,,and they now worked normal. …”

   NHTSA complaint #700102, filed 1998-10

   “Although both the ABS and brake light are on the brakes appear to function properly . The master cylinder was checked and is working properly . The code scanner reads a complete failure of the antilock brake system. The dealer was contacted and advised me I was not covered under the recall for failed brake systems.”

   NHTSA complaint #723314, filed 2000-05
2. 2
   Brakes

   ABS engages unexpectedly and vehicle will not stop

   • 19 complaints (20%)
   • median 258,900 mi at 29.1 yrs old (1 states mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1995–2019

   Owners describe the antilock system activating when it should not, with the pedal becoming hard or pumping on its own and the vehicle sliding or failing to slow. Some say the ABS warning light stays on afterward and that the system had to be reset or repaired more than once. A few report that the brakes locked and the van skidded, and one describes the pedal stiffening halfway through a stop while the vehicle kept moving. Described at highway speeds as well as slower stops, in some cases recurring over years of use.

   1 related service bulletin

   What to check: Check whether the ABS warning light illuminates or stays on, and ask for service records showing ABS module or control unit work. A road test that includes a firm stop on a safe, dry surface can show whether the system engages when it should not.

   2 excerpts from owner complaints in NHTSA records

   “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.”

   NHTSA complaint #736494, filed 2000-11

   “Beginning about a year ago, have had intermittent hard pedal when braking. Occurs rarely, without warning. No ABS light seen but suspect possible ABS malfunction. Pedal does not pulsate but a faint growling, grinding, or buzzing noise is heard. May be ABS motor cycling. During failure brakes are barely operative. Usually returns to normal operation after 2-3 pedal presses. Sometimes pulls sharply left, occasionally right, on brake application. There is no loss of power steering. …”

   NHTSA complaint #11286510, filed 2019-12, 258,900 miles
3. 3
   Body and structure

   Door handles break and rear doors will not open

   • 5 complaints (5%)
   • typically at 12.1 yrs old
   • filed 1995–2009

   Complaints describe exterior and interior door handles snapping off, sometimes on several doors within a short period, and rear or sliding doors that no longer open or latch. One owner reports the sliding door lock engaging before the door was fully closed and damaging the locking mechanism, and another says the rear doors cannot be opened from inside. Owners describe difficulty finding replacement doors and handles. Reports cluster on vans well into their service life, with several owners noting the same failure across multiple doors.

   What to check: Open and close every door, including the rear and sliding doors, and check both interior and exterior handles for looseness or cracks. Confirm the latches hold and that the doors can be opened from inside.

   2 excerpts from owner complaints in NHTSA records

   “The back double door will not open anymore. I can not get into the van to place my sons wheel chair into it. The space in the rear was the reason why I purchased the vehicle. The side door will no longer lock, and the interior light will not come on when the door is open. **dimsii ivoq entry posted after 12-12-02 cut over to artemis**770142”

   NHTSA complaint #10009407, filed 2002-11

   “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.”

   NHTSA complaint #10257005, filed 2009-01
4. 4
   Electrical system

   Melted wiring and electrical shorts under the dash

   • 7 complaints (7%)
   • typically at 5.7 yrs old
   • 3 mention a crash, fire or injury
   • filed 1995–2000

   Owners describe smoke coming from under the dash when the key was turned, melted or bare wiring found afterward, and in one case a fire while the vehicle was parked that totaled it. Another report describes a short in the ignition circuit that damaged the switch and fused other circuits, and a further complaint describes a melted air conditioner fan switch wiring with a burning odor. Reported on vehicles of varying age, with several incidents occurring while the vehicle was parked or being started.

   What to check: Look for scorched or discolored wiring, a burning smell, or repaired harness sections under the dash and around the fuse box. Ask whether any electrical repairs or switch replacements have been done.

   An excerpt from owner complaints in NHTSA records

   “Car parked in driveway. Upon turning key to start, smoke started billowing from under dash. Shut off key, disconnected battery and aired vehicle. Found melted/ bare wiring. Contacted cheverlot custormer service (#990501z66, contact kim hill). Individual reported nothing GM could do to defray costs of repair. Dealer estimate at $2,240.”

   NHTSA complaint #711155, filed 2000-04
5. 5
   Seat belts

   Seat belts fail to hold or retract

   • 7 complaints (7%)
   • typically at 4.5 yrs old
   • 3 mention a crash, fire or injury
   • filed 1995–2005

   Complaints describe shoulder and lap belts that do not hold the occupant during braking or movement, and retractors that fail to click in or to retract on their own. Owners report that dealers were contacted repeatedly without resolution in some cases. Two recalls for this model year concern seat belt anchorage and belt positioning, though complaints describe belts that no longer hold rather than the anchorage condition those recalls address. Reported across many model years of use, with several complaints filed when the vans were already well used.

   Recall 91V164000Recall 91V102000

   What to check: Pull each belt firmly to confirm the retractor locks, check that belts retract fully, and ask whether the seat belt recall repairs were completed for this vehicle.

   2 excerpts from owner complaints in NHTSA records

   “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.”

   NHTSA complaint #10097865, filed 2004-12

   “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.”

   NHTSA complaint #10107408, filed 2005-01

Buying note. This model year draws a large share of brake complaints describing a pedal that sinks and braking power that drops away, so a thorough brake and ABS inspection before purchase is worthwhile. Beyond that, check door hardware, dash wiring, and seat belt function, since those are the other recurring themes in the reports.

Summary written with AI from a sample of 47 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.