1992 Chevrolet Astro Problems

What owners report

Complaints about this model year are dominated by the antilock brake system: owners describe the pedal sinking to the floor, the ABS light coming on and staying on, and stopping distances that lengthen unexpectedly. Many of these reports were filed when the vans were already well past 100,000 miles, and a second common theme is torsion bar breakage in the front suspension on higher-mileage vehicles.

1. 1
   Brakes

   ABS light on and pedal to the floor (antilock brake failure)

   • 41 complaints (31%)
   • median 100,000 mi at 14.1 yrs old (3 state mileage, few)
   • 10 mention a crash, fire or injury
   • filed 1995–2012

   Owners describe the brake pedal dropping toward the floor during stops, usually in harder or quicker braking, with the ABS warning light coming on and in some cases staying on afterward. Several reports say the vehicle did not stop as expected and that the van rear-ended another vehicle or slid through a stop sign. According to the complaints, dealers often could not duplicate the problem, replaced the ABS modulator or valve body, or told owners the vehicle was out of warranty; one owner reported the ABS module was no longer available. Reported across a wide mileage range, from around 36,000 miles up past 100,000, with no clear seasonal pattern in the sample.

   What to check: Ask whether the ABS light is currently on and whether the modulator, valve body or module has been replaced; note that some owners had the ABS disabled to get back to conventional braking, so confirm the system is intact and functioning.

   2 excerpts from owner complaints in NHTSA records

   “Was driving and a truck pulled out of drive way in front of me. Hit the brakes and they worked for a split second but then went out causing an accident. Since that they brake tight and ABS light came on and continues to stay on at all times now. I do have brakes just not anti-lock. Have checked the whole system to fix and found that it is a common problem. The ABS module is no longer available so can not remedy this problem. I live in a state that has safety and emissions tests that it will not pass. …”

   NHTSA complaint #10469227, filed 2012-08, 122,740 miles

   “After a quick stop to avoid an accident, which the quick stop had to turn right to avoid the other vehicle, the ABS failed or so the idicator ligits says. Had system checked and ABS valve body had to be replaced. Cost $1400.00 I know NHTSA was investigating the GM antilock brake systems, thought it would be helpful. Would appreciate any news as to possible reimbursement by GM for faulty ABS systems. Proper use of the brake system was done. (I.e. Full brake without pumping).”

   NHTSA complaint #540194, filed 1998-08
2. 2
   Suspension

   Front torsion bar breaking

   Mentioned in 7 of 60 sampled complaints

   Owners report the front torsion bar snapping, sometimes while parked or pulling into a driveway, and in other cases while driving, leaving the front of the van dropped several inches or a side sitting low. One owner said the dealer described it as a common problem; another said the manufacturer told them it was not a recall and offered no assistance. A complaint attributes the breakage to corrosion where road debris and water reach the bar. Mostly reported on vehicles above 150,000 miles; one report is at 196,000 miles.

   What to check: Look for a van sitting unevenly at the front or with a recently replaced torsion bar, and ask whether both bars were replaced and whether seals were fitted at the support tube.

   2 excerpts from owner complaints in NHTSA records

   “The torsion bar on driver's side broke. Consumer contacted the manufacturer, and was told that the prpoblem was not a recall, and there was nothing they could do.”

   NHTSA complaint #10087134, filed 2004-08, 196,000 miles

   “Torsion bar broke while driving into driveway. Gm and dealer fail to admit the design defect which was corrected on 1997 vechicles and is now required for repairs. No torsion bar seals were ever installed per GM's manual accordding to my dealer mechanic. This seal was intended to prevent road debree and water from entering the support tube and causing the rust, stress corrosion and eventual failure of the torsion bar. …”

   NHTSA complaint #751731, filed 2001-09
3. 3
   Electrical system

   Under-dash and wiring fires

   Mentioned in 4 of 60 sampled complaints

   A small group of complaints describes electrical fires, including a fire that began under the dash while the van was parked in a garage, an engine compartment fire attributed to an electrical short while driving, and an ignition switch that smoked and caught fire when starting the vehicle. One owner reports a cigarette lighter that failed to pop out and began burning the wiring harness. No mileage pattern in the sample; the reports come from vans of varying age and use.

   What to check: Inspect under the dash and in the engine bay for scorched wiring or a burnt smell, check that the cigarette lighter and accessories work, and ask whether any wiring repairs have been done.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle was parked in garage. Smelled smoke. Checked and fire was inside, looked as if started under dash and spread to interior of the van. Fire department came and put fire out. Dealer /manufacturer aware of the problem.”

   NHTSA complaint #833313, filed 1999-01

   “Cigarette lighter was depressed and would not pop back out. Rather than blowing the 30 amp fuse ,it started burning wiring harness, causing fire hazard.”

   NHTSA complaint #855617, filed 2000-01

Buying note. The antilock brake system is the item to look at first: confirm the ABS light is not on and that the system has not been disconnected, since replacement parts are reported as hard to find. On higher-mileage vans, also have the front torsion bars and steering linkage checked before driving it regularly.

Summary written with AI from a sample of 60 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.