2002 Chevrolet Astro Problems
- Complaints
- 70filed with NHTSA
- Median mileage
- 60,000miles, 45 complaints with mileage
- Recalls
- 1campaigns on record
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 17 mpgcombined, 4.3L 6-cyl RWD · 15 city / 20 hwy
Sources: NHTSA records for the 2002 Chevrolet Astro (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of this model year most often describe braking problems, especially the antilock system engaging at low speeds and the brake pedal traveling to the floor, along with ignition and wiring faults that can cause stalling or loss of power. Reports span a wide mileage range, with many brake complaints filed between roughly 25,000 and 100,000 miles and several electrical and steering complaints at higher mileage.
- Brakes
ABS activates at low speed; pedal to floor
- 16 complaints (23%)
- median 41,000 mi at 3.8 yrs old (12 state mileage)
- filed 2003–2015
Complaints describe the antilock brakes engaging without warning at very low speeds, such as pulling into a parking space or coming to a stop, which owners say increases stopping distance. Some report the brake pedal traveling to the floor and having to pump the brakes to stop, and a few mention the master cylinder or brake lines being replaced. Dealers reportedly told some owners this was a common condition and cleaned corroded wheel sensors, though the problem often returned. Mostly reported between about 25,000 and 100,000 miles, often at low speeds on dry pavement.
What to check: Test the brakes at walking speed in a parking lot and listen for ABS chatter or a long pedal; ask whether the Hydro-Boost unit or wheel sensors have been serviced.
2 excerpts from owner complaints in NHTSA records
“I began having a situation where my anti-lock brake system would activate at slow speeds <10 MPH such as when pulling into a parking space - this results in the vehicle going forward farther than it normally would - please note that I did not have any accidents. I took it to the dealer which indicated that it was a common problem and they may be able to clean the sensors of corrosion (they did note that the sensors are lightly built and could break requiring replacement during the cleaning process - which they did). …”
NHTSA complaint #10135013, filed 2005-08, 42,000 miles“Dt: shift indicator was indicating the wrong gear. While driving the road the indicator was moving, but the shifter itself. Every time I drove the vehicle this happened. It was taken to dealer to fix and stated there were a lot of complaint. This occurred about a month ago antilock brakes are applying when dry. When going about 3-4 MPH the antilock brakes will engaged. This problem was random. Have not taken for repairs.”
NHTSA complaint #10119980, filed 2005-05, 34,600 miles - Seat belts
Seat belts fail to lock or restrain
- 6 complaints (9%)
- median 77,650 mi at 3.5 yrs old (2 state mileage, few)
- 2 mention a crash, fire or injury
- filed 2002–2015
Owners report front and rear seat belts that extend but do not lock or retract properly, leaving slack during sudden stops, and some say the belts did not restrain occupants in a collision. A few complaints concern rear belts that fit children poorly or were not installed correctly. Owners report being quoted a repair cost by the manufacturer, with no recall covering the belts. Reported from new up to about 95,000 miles, with several mentions of failure during hard braking or a crash.
What to check: Pull each belt out fully and check that it locks with a sharp tug and retracts smoothly, including the rear belts.
2 excerpts from owner complaints in NHTSA records
“High speed car accident on 1/3/07 driver seat belt did not work correctly, belt did not lock upon hard braking or upon car crash I hit my chest on steering wheel and my knees on dashboard, my airbag did not deploy either.”
NHTSA complaint #10178492, filed 2007-01“The brakes made a squealing noise, and was replaced. After they were replaced, the brakes locked up which resulted in an accident. When the brakes locked, the vehicle ran into a snowbank. On the second occasion, the brakes locked and slid into the person in front. The vehicle was rear ended and the air bags did not deploy and the seat belts were inoperative. The consumer requested money back.”
NHTSA complaint #10019695, filed 2003-07, 60,000 miles - Brakes
Brake pedal moves or self-applies on full turns
- 16 complaints (23%)
- median 38,000 mi at 4.1 yrs old (12 state mileage)
- 4 mention a crash, fire or injury
- filed 2003–2015
Complaints describe the brake pedal moving or applying on its own while the steering is held at full lock, and in some cases the pedal dropping with a loss of braking. Several reports mention brake fluid leaking from rusted steel lines near the rear axle, or the master cylinder being replaced after a sudden loss of brakes. Multiple service bulletins discuss the Hydro-Boost unit not being serviceable and needing replacement for this symptom. Reported from low mileage up to around 170,000 miles, sometimes after years of use in cold or salted-road conditions.
What to check: With the engine running, hold the wheel at full lock and watch the pedal; inspect the rear brake lines for rust, and ask whether the Hydro-Boost has been replaced.
2 excerpts from owner complaints in NHTSA records
“I got in my van to drive to a store and the brake pedal went right to the floor. There was brake fluid leaking from near the rear tire. The steel hard brake line running from the ABS unit to the rear axle is rusted through and is leaking. This was a sudden event. Also the fuel lines look to be just as bad. I'm sure stainless steel lines would not have added much to the vehicles cost and would have prevented this hazard and expense.”
NHTSA complaint #10706501, filed 2015-04, 113,000 miles“On march 26, 2008, I took my 2002 chevy Astro van to be serviced. Mileage 93,829,I had no brakes. The master cylinder was determined to be the cause of the failure and was replaced. On april 12, 2008, once again I had no brakes, this time it resulted in me getting into and accident. I took the van back to the same repair shop. When they put it on the lift they said the whole braking system was melted until the point of the hose bursting. He said he never saw anything like this in his 20 years of service. …”
NHTSA complaint #10248363, filed 2008-11, 94,339 miles - Electrical system
Engine stalls or runs poorly from ignition moisture
- 5 complaints (7%)
- median 28,200 mi at 3.4 yrs old (3 state mileage, few)
- filed 2004–2007
Owners describe the engine dying in traffic or failing to restart, which they attribute to moisture and corrosion inside the distributor cap and rotor. Complaints say the cap and rotor were replaced repeatedly and the problem returned after a while, and some report misfires, lack of power and rough running before a stall. Dealers reportedly replaced the cap and rotor but did not always resolve the recurring fault. Most often reported between about 25,000 and 65,000 miles, frequently in wet or humid weather.
What to check: Ask how often the distributor cap and rotor have been replaced, and inspect them for corrosion; a test drive in wet weather can reveal a stumble or stall.
2 excerpts from owner complaints in NHTSA records
“I only drive this 2002 Chevrolet Astro van in our small town because I am terrified to drive it on expressways or in heavy traffic because the distributor cap collected moisture and the engine stopped in heavy traffic almost causing terrible accidents three times in the past 8 months. Last week I drove the van into town. I keep a close watch on all the gauges because of the previous problems. When I left the house all the gauges on the dash were working and the battery was between 12-14 volts. …”
NHTSA complaint #10110306, filed 2005-02, 28,200 miles“I attempted to make a left hand turn across two lanes of on coming traffic (speed limit 55 MPH). I push down on the accelerator, the van moved into the on coming traffic lanes and the engine died. Cars had to quickly apply breaks to avoid hitting my van. It took about 20 seconds to get the van started and out of the intersection. The van was towed into courtesy Chevrolet and the distributor cap and rotator were replace. I was told everything was corrected. …”
NHTSA complaint #10110302, filed 2005-02 - Electrical system
Brake and hazard lights stop working
Mentioned in 4 of 60 sampled complaints
Complaints describe the brake lights and hazard lights failing, sometimes intermittently, with owners noting that moving the hazard switch or pressing the pedal could make them work again. Several owners say the dealer told them their vehicle was not covered by the lighting switch recall even though the failure matched it. One recall addresses an open circuit in the stop and hazard lamp circuits on certain vehicles of this era. Reported across a wide mileage range, from about 70,000 to over 160,000 miles.
What to check: Have someone watch the brake and hazard lights while you press the pedal and try the switch, and check by VIN whether the lighting switch recall applies and was done.
2 excerpts from owner complaints in NHTSA records
“I have owned 3 Astro vans, ?89 and 92 (made in USA) previously and liked them so well I bout another one 2002 (made in mexico). Within 60,000 miles rear seat fabric started to come apart, driver door power windows and locks stopped working, windshield washer hoses rotted, interior fan blower switch failed (twice), driver arm rest vinyl splitting in many areas, steering wheel mounted hazard light switch caused break and signal lights to blow fuses (this was fixed as recall), rear cargo door handle broke off, fuel tank gas level indicator …”
NHTSA complaint #10196594, filed 2007-07“Hazard lights stop working and causes the trailer lights not to work( no left turn, right turn or brakes to trailer harness). Signals and brakes on van works okay but no hazards.”
NHTSA complaint #10264251, filed 2009-04, 161,000 miles
Buying note. This model year draws repeated brake and electrical complaints, so a pre-purchase inspection focused on the antilock brakes, brake lines and ignition components is worthwhile. Confirm by VIN which recalls and service bulletins apply and whether they have been performed.
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.
NHTSA recorded 70 consumer complaints for the 2002 Chevrolet Astro. 45 of the complaints include a mileage, and 42% of those were filed for vehicles with under 50,000 miles; the median is 60,000 miles. Of all complaints, 7 involved a crash, 3 a fire, 4 an injury, 4 a death, according to the filers. NHTSA lists 1 recall campaign and 308 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Brakes23 33%
- Electrical system13 19%
- Seat belts8 11%
- Steering7 10%
- Body and structure5 7.1%
- Tires5 7.1%
- Vehicle speed control5 7.1%
- Air bags4 5.7%
Also reported: Engine cooling (3), Exterior lighting (3), Electronic stability control (2), Equipment (1), Fuel system (1), Other or unknown (1).
Example complaints
Brakes: “Abs coming on at very low speeds on dry pavement (under 5mph/8kmh). It doesn't do it every time, but quite often at low speeds, like coming to a red light, stop sign or parking. Of course, there is no need for the ABS come on at such low speeds and especially not on dry pavement.”
NHTSA complaint #10432683, filed 2011-10, 106,872 milesElectrical system: “I was driving and all of a sudden, the dash lights went out and the car died. I lost power steering, and I coasted to the side of the road. Come to find out the fuse box was hot and there was a few fuses that were blown. I replace the blown fuses and drove home. When I got home and turned off the van, I couldn't get it start I looked at the same fuse and they were blown again. The van now sits in the driveway till I figure this out. Because it is too dangerous to drive.”
NHTSA complaint #10619259, filed 2014-08, 100,145 milesSeat belts: “I have recently purchased a new custom van from this dealership. My rear seatbelts are not installed properly, therefore, I can not provide safe transportation for my grandchildren. The dealer and the GM representative have been extremely non-cooperative as well as GM contractor who customized the van. I am turning to you for any assistance. I pray that you can help my wife and I with a resolution to this problem. I feel we are being taken advantage of because of our age and we can not fight back (attorney) because of our limited income. Thank you. Dt”
NHTSA complaint #769226, filed 2002-11Steering: “My 2002 Astro van has been in the service dept. At ron carter in alvin texas 11 times, 7 times for the same problem, the steering. Electrical problems 5 times, the light flashing and the locks clicking constantly. The back door broke twice for no apparent reason, the fuel pump failing and numerous other problems, well the electrical problem was supposedly fixed, but now is acting up again, I have 4 children and need a safe vehicle to drive in with my kids.”
NHTSA complaint #10016966, filed 2003-05, 37,000 milesMileage when problems were reported
42% of the 45 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 31,000 and 106,872 miles.
Complaints by year filed
Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 2002 Chevrolet Astro. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.
| Version | Overall | Frontal | Side | Side pole | Rollover |
|---|---|---|---|---|---|
| Astro · sedan | not rated | 3 / 4 | — | — | — |
Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.
Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.
Fuel economy and running cost
EPA ratings for each 2002 Chevrolet Astro version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Astro 2WD (cargo) | 4.3L 6-cyl | 4-speed automatic | 15 | 20 | 17 | $3,950 |
| Astro 2WD (passenger) | 4.3L 6-cyl | 4-speed automatic | 14 | 18 | 16 | $4,200 |
| Astro AWD (cargo) | 4.3L 6-cyl | 4-speed automatic | 14 | 18 | 15 | $4,450 |
| Astro AWD (passenger) | 4.3L 6-cyl | 4-speed automatic | 13 | 17 | 15 | $4,450 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 05V099000Mar 14, 2005Exterior lighting › Brake lights › SwitchCovers: Chevrolet Astro 2001–2002, GMC Safari 2001–2002
On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative.
Recall details for the 2002 Chevrolet Astro → · Check a VIN at nhtsa.gov/recalls
NHTSA investigations
- PE04072Loss of brake lamp illuminationClosed · Oct 19, 2004
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 308 on record; the latest 10 are shown.
- 11020816Jul 18, 2025Other or unknown. This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- 11014455Feb 20, 2025Other or unknown. This 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…
- 11009156Oct 25, 2024Electrical system. This 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…
- 11007744Sep 12, 2024Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical…
- 11007743Sep 12, 2024Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical…
- 11006621Aug 26, 2024Electrical system. Vehicle 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…
- 11006421Jul 24, 2024Transmission and drivetrain. GM 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…
- 11004761Jun 28, 2024Fuel system, Engine. This 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…
- 11004557Jun 17, 2024Other or unknown. This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312Jun 6, 2024Electrical system. This 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…
Other model years of the Chevrolet Astro
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2005 | 9 | 24,500 | 0 | — | 16 | — | Not enough data |
| 2004 | 14 | 70,000 | 0 | — | 16 | — | Not enough data |
| 2003 | 62 | 67,000 | 1 | — | 16 | Not compared (before 2008) | Falling |
| 2002 | 70 | 60,000 | 1 | — | 17 | Not compared (before 2008) | Falling |
| 2001 | 91 | 62,500 | 1 | — | 17 | Not compared (before 2008) | Stable |
| 2000 | 175 | 65,000 | 0 | — | 17 | Not compared (before 2008) | Falling |
| 1999 | 133 | 74,900 | 1 | — | 16 | Not compared (before 2008) | Stable |
| 1998 | 241 | 88,000 | 3 | — | 16 | Not compared (before 2008) | Stable |
| 1997 | 360 | 91,000 | 4 | — | 17 | Not compared (before 2008) | Stable |
| 1996 | 263 | 101,000 | 4 | — | 17 | Not compared (before 2008) | Stable |
| 1995 | 446 | 113,250 | 3 | — | 17 | Not compared (before 2008) | Stable |
| 1994 | 328 | 120,000 | 2 | — | 17 | Not compared (before 2008) | Stable |
| 1993 | 135 | 145,000 | 1 | — | 17 | Not compared (before 2008) | Stable |
| 1992 | 132 | 111,370 | 1 | — | 17 | Not compared (before 2008) | Stable |
| 1991 | 95 | 258,900 | 3 | — | 17 | Not compared (before 2008) | Stable |
| 1990 | 68 | 116,042 | 4 | — | 19 | Not compared (before 2008) | Stable |
| 1989 | 57 | 44,594 | 3 | — | 18 | Not compared (before 2008) | Stable |
| 1988 | 56 | — | 2 | — | 18 | Not compared (before 2008) | Stable |
| 1987 | 29 | 95,451 | 2 | — | 18 | Not compared (before 2008) | Stable |
| 1986 | 23 | — | 1 | — | 20 | — | Stable |
| 1985 | 5 | — | 3 | — | 18 | — | Not enough data |
All Chevrolet Astro model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2002 Chevrolet Astro?
Owners of this model year most often describe braking problems, especially the antilock system engaging at low speeds and the brake pedal traveling to the floor, along with ignition and wiring faults that can cause stalling or loss of power. The issues reported most often: ABS activates at low speed; pedal to floor; Seat belts fail to lock or restrain; Brake pedal moves or self-applies on full turns.
How many NHTSA complaints does the 2002 Chevrolet Astro have?
NHTSA recorded 70 consumer complaints for the 2002 Chevrolet Astro as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2002 Chevrolet Astro is reported most often?
Brakes is named most often, in 23 complaints (33% of the total), followed by electrical system with 13.
Has the 2002 Chevrolet Astro been recalled?
NHTSA lists 1 recall campaign for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2002 Chevrolet Astro get?
The EPA rates the 2002 Chevrolet Astro (Astro 2WD (cargo), 4.3L 6-cyl) at 17 mpg combined, 15 city and 20 highway, with an estimated annual fuel cost of $3,950 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2002 Chevrolet Astro reported?
Among the 45 complaints that include a mileage, the median is 60,000 miles and the middle half falls between 31,000 and 106,872 miles; 42% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.