Skip to content
Chevrolet AstroModel year report

2004 Chevrolet Astro Problems

Complaints
14filed with NHTSA
Median mileage
70,000miles, 13 complaints with mileage
Recalls
0campaigns on record
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
16 mpgcombined, 4.3L 6-cyl RWD · 14 city / 19 hwy

Sources: NHTSA records for the 2004 Chevrolet Astro (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error

NHTSA recorded 14 consumer complaints for the 2004 Chevrolet Astro. The part named most often is brakes, with 7 complaints (50% of the total), followed by electrical system (2) and vehicle speed control (2). 13 of the complaints include a mileage, and 31% of those were filed for vehicles with under 50,000 miles; the median is 70,000 miles. Of all complaints, 1 involved a crash, 1 a fire, 3 an injury, according to the filers. NHTSA lists 0 recall campaigns and 380 technical service bulletins for this model year. Brakes complaints overlap with 16 technical service bulletins filed under the same part. Electrical system complaints overlap with 73 technical service bulletins filed under the same part.

This model year has fewer than 25 complaints on record, so the numbers below can change a lot with a few new reports.

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.

Example complaints

Brakes: “Antilock braking system warning lights and brake light came on when I was entering the freeway. The lights continue to come on whenever I am driving. I had it checked at corning Chevrolet and was told the part alone was $900 plus labor to replace it. The brakes work, but not the antilock system installed by the manufacturer.”

NHTSA complaint #10717422, filed 2015-05, 50,500 miles

Electrical system: “When my wife returned to our 2004 Chevrolet Astro van, the vehicle seemed to have a dead battery. The car would not turn over or fire the ignition. After having the battery and starter checked, we were told the battery was drained and they were able to charge the battery. The starter checked good. The car seemed to have a dead short when trying to start and/or boost. After replacing all components, the van started, however, when I put my foot on the brakes, there was no brake pressure on the pedal. It appeared that we were losing brake fluid under the vehicle from a ruptured line. …”

NHTSA complaint #10305971, filed 2010-02, 126,000 miles

Vehicle speed control: “Once or twice per year when using cruise control, when I touch brake to deactivate cruise, it doesn't disengage. I then have to stand on brake with all my effort to stop van and pull over to put in park. Engine continues racing til I turn key off. Then everything ok til next time maybe months later. Switck on brake petal is ok. Once in the winter, cruise control pushed me into an intersection. Luckily other traffic realized I couldn't stop. No codes show up to identify cause. Been doing this 4 or 5 years intermittently. Even tho this van is 16 years old, it only 6has 90000 miles on it. …”

NHTSA complaint #11321778, filed 2020-04, 70,000 miles

Air bags: “My wife was driving a 2004 chevy Astro van approx. 35-40 MPH on a two-way street. Another driver from the opposite direction cut across into her lane and had a head-on collision. She suffered a broken wrist & bruised ribs. She had three of our children in their seats. They were shaken and had seatbelt bruises. The van was not drivable and was towed away. The police & the tow driver reported that the airbags did not deploy. We have some expectation that the airbags would have secondary role to minimize injuries. …”

NHTSA complaint #10245434, filed 2008-10, 68,000 miles

Mileage when problems were reported

31% of the 13 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 46,000 and 126,000 miles.

8%0–1015%10–258%25–5023%50–758%75–10031%100–1508%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (13 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 70,000 miles.

Complaints by year filed

Fewer than 15 complaints, too few for a reliable trend.

200520072010320142020
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Crash test ratings

NHTSA's 5-Star Safety Ratings for the 2004 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.

VersionOverallFrontalSideSide poleRollover
Astro · sedan not rated3 / 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 2004 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).

VersionEngineTransmissionCityHwyComb.Fuel / yr
Astro 2WD (cargo)4.3L 6-cyl4-speed automatic141916$4,200
Astro 2WD (cargo) Conversion4.3L 6-cyl4-speed automatic141815$4,450
Astro 2WD (passenger)4.3L 6-cyl4-speed automatic141916$4,200
Astro AWD (cargo)4.3L 6-cyl4-speed automatic141815$4,450
Astro AWD (cargo) Conversion4.3L 6-cyl4-speed automatic121614$4,800
Astro AWD (passenger)4.3L 6-cyl4-speed automatic121614$4,800

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

NHTSA lists no recall campaigns for the 2004 Chevrolet Astro in the data used here. A recall can apply to some vehicles of a model year and not others, so check a specific vehicle by VIN at nhtsa.gov/recalls.

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. 380 on record; the latest 10 are shown.

See all 380 bulletins →

Other model years of the Chevrolet Astro

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
2005924,5000—16—Not enough data
20041470,0000—16—Not enough data
20036267,0001—16Not compared (before 2008)Falling
20027060,0001—17Not compared (before 2008)Falling
20019162,5001—17Not compared (before 2008)Stable
200017565,0000—17Not compared (before 2008)Falling
199913374,9001—16Not compared (before 2008)Stable
199824188,0003—16Not compared (before 2008)Stable
199736091,0004—17Not compared (before 2008)Stable
1996263101,0004—17Not compared (before 2008)Stable
1995446113,2503—17Not compared (before 2008)Stable
1994328120,0002—17Not compared (before 2008)Stable
1993135145,0001—17Not compared (before 2008)Stable
1992132111,3701—17Not compared (before 2008)Stable
199195258,9003—17Not compared (before 2008)Stable
199068116,0424—19Not compared (before 2008)Stable
19895744,5943—18Not compared (before 2008)Stable
198856—2—18Not compared (before 2008)Stable
19872995,4512—18Not compared (before 2008)Stable
198623—1—20—Stable
19855—3—18—Not enough data

All Chevrolet Astro model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2004 Chevrolet Astro have?

NHTSA recorded 14 consumer complaints for the 2004 Chevrolet Astro as of Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Chevrolet Astro is reported most often?

Brakes is named most often, in 7 complaints (50% of the total), followed by electrical system with 2.

Has the 2004 Chevrolet Astro been recalled?

NHTSA lists no recall campaigns for this model year in the data used here. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Chevrolet Astro get?

The EPA rates the 2004 Chevrolet Astro (Astro 2WD (cargo), 4.3L 6-cyl) at 16 mpg combined, 14 city and 19 highway, with an estimated annual fuel cost of $4,200 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 Chevrolet Astro reported?

Among the 13 complaints that include a mileage, the median is 70,000 miles and the middle half falls between 46,000 and 126,000 miles; 31% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 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.