1996 Chevrolet Astro Problems

What owners report

Owners of this model year most often report the front torsion bar snapping, which drops the front of the van onto the tire, sometimes while parked in a driveway and sometimes while driving. Windshield wiper motors that work intermittently or quit in rain, and brake pedal complaints where the pedal sinks toward the floor, are the other frequently described problems, with many reports arriving between roughly 70,000 and 130,000 miles.

1. 1
   Suspension

   Front torsion bar breaks and front end drops

   • 39 complaints (15%)
   • median 83,000 mi at 7.9 yrs old (7 state mileage, few)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $844 (median of 6 quotes)
   • filed 1999–2010

   Complaints describe a loud bang or popping noise followed by the front of the van dropping several inches, in some cases resting on the front tire. Several owners say this happened while the vehicle was parked or backing out of a driveway, while others report it at low speed on the road. According to the complaints, dealers replaced the bar and often said both sides had to be changed because the part had been redesigned; owners describe the failed bar as heavily rusted or corroded where it seats in its retaining sleeve. Mostly reported between roughly 70,000 and 130,000 miles, often after the van had been driven and then parked.

   What to check: Look closely at both torsion bars and the sleeves where they mount for heavy rust or dirt packing, and ask whether either bar has been replaced with the updated part.

   2 excerpts from owner complaints in NHTSA records

   “My wife went to move our 1996 Chevrolet Astro van and when she backed up the right front tire was rubbing on the wheel well. Upon further investigation it was determined that one of the torsion bars broke. When I called my local dealer I found the parts were readily available but I would have to replace both sides because they had been updated . The parts alone were over $500.00. …”

   NHTSA complaint #10046024, filed 2003-11, 83,000 miles

   “Vehicle was backing out of driveway, when a loud noise proceeded the front driver side of the van collapsing onto the front tire. The Chevrolet dealer informed me that the torsion bar had failed, and as the part had been redesigned, the passenger side would also be replaced. I requested the parts be returned, and after visually inspecting, it is very apparent that the part failed due to severe rust and corrosion. …”

   NHTSA complaint #10008103, filed 2003-02
2. 2
   Visibility (wipers, defrost, mirrors)

   Windshield wipers stop or work intermittently

   • 48 complaints (18%)
   • median 39,000 mi at 1.7 yrs old (1 states mileage, few)
   • filed 1997–2003

   Owners describe wipers that sometimes do not move, run only on high speed, stop mid-wipe, or quit entirely during rain, while working normally in dry weather. Several complaints tie this to cracked solder joints on the wiper motor controller board, and some owners note their van was not covered by the wiper motor recall. Complaints also mention power window motors failing, most often in winter or rain. Reported across a wide mileage range, often in wet weather or after the vehicle warms up.

   Recall 03V159000

   What to check: Test the wipers in every speed and intermittent setting, and check by VIN whether the wiper motor recall was completed.

   2 excerpts from owner complaints in NHTSA records

   “I have a 1996 Chevrolet Astro van. I've replaced the driver and passenger side power window motor's four times, each. Our company has 26 vehicles, all Astro van's and all have the same problem. I just received a recall notice about the wiper motor on this vehicle. The power window motor definitely is more of a problem. I can't believe that there hasn't been a recall. In the winter, you'll being driving, lower the window and all of a sudden can't get it up. It's even more of a problem when it rains. Please check into this. …”

   NHTSA complaint #10030645, filed 2003-08, 39,000 miles

   “Whenever windshield wipers are in use, they can be used only in high position. After vehicle has warmed up, wipers would not work properly in the rain. The more moisture in the atmosphere, the worse the wipers work or stop completely. When parked in garage & heater drys out wipers,they work fine on high, but not on low.”

   NHTSA complaint #835918, filed 1999-03
3. 3
   Brakes

   Brake pedal sinks toward the floor

   • 28 complaints (11%)
   • median 177,643 mi at 19.0 yrs old (2 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1997–2015

   Complaints describe the brake pedal slowly or suddenly going to the floor, requiring pumping to stop, with longer stopping distances; some mention the ABS light coming on. One owner reported pinholes leaking in the steel brake lines from front to rear. Others describe pulsation and repeated rotor turning, and one service bulletin covers a pedal that moves down or self-applies during near-full-lock turns. Mostly described on vehicles between about 100,000 and 130,000 miles, though some reports come at lower mileage.

   1 related service bulletin

   What to check: Ask when the brake fluid and lines were last inspected, look for wet or rusted sections along the steel lines, and test the pedal for firmness and pulsation on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “The failure of anti-lock brakes to work properly (wheels lock up), has caused me to slide into an intersection and almost get broadsided, and it has caused me to nearly slide into a truck in a parking lot. The front rotors have had to be turned 7 times - 6 in the last 13 months. The brakes will pulsate because the rotors warp about every 2 months.”

   NHTSA complaint #708943, filed 1999-07

   “Pin holes in steel brake lines causing complete brake failure. Fortunately vehicle was sitting when brake petal was applied for starting. When pressing brake to start vehicle, petal went completely to floor. When checking under vehicle to analyze problem, pin holes leaks were observed in various places from front to rear in steel lines. I fear what may have happened had the vehicle been in motion, around pedestrians, and/or, on the road.”

   NHTSA complaint #10816261, filed 2015-12, 120,227 miles
4. 4
   Air bags

   Airbags not deploying in frontal impacts

   • 14 complaints (5%)
   • median 106,000 mi at 7.5 yrs old (3 state mileage, few)
   • 12 mention a crash, fire or injury
   • filed 1996–2003

   Several owners report frontal or rear-end collisions in which neither front airbag deployed, sometimes with injuries described. The complaints span direct center hits, bumper contact, and being struck from behind and pushed into the vehicle ahead. In a couple of cases the same report also questions brake or ABS performance during the event. Reports span a wide mileage range, from roughly 35,000 to 190,000 miles.

   What to check: Check for any airbag warning light and ask whether the airbag system has been scanned for stored fault codes; a pre-purchase inspection can confirm the system reports ready.

   2 excerpts from owner complaints in NHTSA records

   “This vehicle was involved in 3 accidents all with the front end. The air bags never deployed in any of the accidents. 2 of the accidents were dead center hits. 1 accident involved the bumper. Ph **dimsii ivoq entry posted after 12/12/02 cut over to artemis**769300”

   NHTSA complaint #10007520, filed 2002-11, 106,000 miles

   “While at a complete stop vehicle was rear ended at 50 MPH . Upon impact, vehicle was pushed forward, and rear ended the vehicle in front. None of the air bags deployed, and driver sustained back and neck injuries.”

   NHTSA complaint #10046222, filed 2003-11, 130,000 miles
5. 5
   Transmission and drivetrain

   Transmission fluid leak, slipping or failure

   • 13 complaints (5%)
   • median 110,000 mi at 9.4 yrs old (1 states mileage, few)
   • filed 1997–2008

   Owners describe losing power with white smoke and transmission fluid spraying underneath after a cooler line came loose, and others report slipping, a check-engine light, and transmission replacement. One complaint links rear axle work to later transmission trouble. Described mostly between about 70,000 and 180,000 miles.

   What to check: Check transmission fluid level and color, look for leaks or residue around the cooler lines and pan, and note any delayed or harsh shifts on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “I was driving down the interstate at 65 miles per hr. And all of a sudden I saw white smoke coming from the back of my van, it looked like the van was on fire, I lost all power to the van, and had no pick-up or speed. I had to divert the van to the shoulder of the highway. When I looked under the hood I found that the transmission cable had come unattached, and I had transmission fluid all over the ground. There were no warning signs whatsoever. Transmission fluid sprayed all the way to my back windshield of the van.”

   NHTSA complaint #10112236, filed 2005-02, 110,000 miles

   “It all started with the rear axle. Several attempts to get dealer to reproduce the problem. Dealer stated wait until it gets worse so we can see the problem.problem discovered by dealer. Drive away with car and the rear axle fell out. Now dealer agrees to replace rear end gear box. Now transmission is starting to fail. Too far away from dealer to get tow. Left it in a transmission diagnostic center. My question is to you is can the problems that I was having with the rear end & the wheel falling off cause damage now to the transmision”

   NHTSA complaint #706900, filed 1999-05

Buying note. On this model year, inspect the front torsion bars for rust and the wiper and brake systems closely, since those are the most frequently described problems; a pre-purchase inspection covering the suspension, brake lines, and wiper operation is worthwhile before deciding.

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.