AC & Heater complaints by model year
Which parts fail
Components named in complaints (air conditioning, heater, defroster, HVAC controls).
Mileage when the problem started
What owners report
Ant-lock brake system had to replaced. Also, since purchase in May 2000, following components had to be replaced or repaired: lights on dashboard coming off and on/passenger side seatbelt tightened and won't release/driver's seat had loose bolts and moved/driver and passenger doors rattled/ mouldings inside fell off/passenger's window stuck/tv came on and off on its own while driving, replaced twice/interior lights stopped working when in park/ engine idled/ lights inside flickered/ fuel sender inoperative/ wires in ceiling rattling,air conditioner in rear not working/ replaced heater that did not work in rear, and passenger's airbag cover not flushing, and consumer worried it May deploy at any time.
The Astro/safari has a brittle vacuum line that crosses over the thermastat area of the intake manifold. This plastic vacuum line is easily broken in routine service of the air filter or rubbing on other component parts. When this vacuum hose is broke...air select to defroster and other vent positions is lost-causing lack of visability. I believe this is a safety issue. I believe there is a GM TSB on this and it shows up on intranet threads yet GM dealers allow customers be to subjected to a $70. Diagnosis. This is a known safety problem. This vacuum hose is a "front row"stocked part at most dealers. I believe a lot of 95-03 Astro/safari owners will have or have had this vacuum hose breakage.
Brakes have been severly worn out consumer stated the seatbelts, arm rests, console the trim on the seat cushion has torn, there is wind noise from high top roof, window is loose, radio is inoperative, power steering fluid leaking, steering coolumn is making a noise, weatherstrip coming off of back door, tires shake, there is a hard thump whe going over bumps, cigarette lighter is inoperative,transmission shifts hard, pressure guage gets stuck, window gets stuck, there are no low beam lights, windshield wipers are inoperative, door lock do not come all the way up, the front end of vehicle dips, and the shocks feel weak, the lifgate does not stay open, interior lights stay on to long, vehicle remote is inoperative, sliding door is hard to open at times, oil pressure guage reads high, refrigerator not operating from rear socket, heating system is inoperative, battery goes dead.
Switch on dash board for rear air conditioner fan control was over heating in the high speed position. I tried to turn it off and could not and it was hot to the touch. I knew how to remove the switch while my wife was driving. The switch was over heating and partially melted the connector and destroyed the switch. I believe that if I did not disconnect the switch the possibility of a fire was there.
We noticed a smell of burning wires. We were parked, so I pulled the rear A/C switch out of the dash. I found that this switch, which is all plastic, had been shorted and partially melted. I disconnected the switch. The scary part for me is that the fuse never blew. I am an aircraft mechanic and feel that I was able to avoid an electrical fire by having some mechanical ability. If my wife had been in the van alone with our children this would have been a very serious and possibly devastating problem. I contacted the manufacturer and lodged a complaint with Chevrolet customer assistance ( file # c01463026 ). Chevrolet told me that no recall had been issued on this switch and that all I could do is take it to the dealer. The dealer wants to put in a replacement switch, same type. …
Brake problems on 1997 Chevrolet Astro van. The consumer stated that more brake work was needed. The brakes had rusted and needed to be turned, the A/C was not blowing cold and there was a heating concern. The rear axle seals and differential gaskets were leaking..
Switch for rear ac/heat burned and smoked when I turned it on. Premier motor coach installed it. This is the second failure in this vehicle. Last summer, it didn't blow any air. I spoke with premeir as the latest motor lasted 13000 miles. Had I put the heat on and left the car, a fire would have started. I would like to know where else I can turn to. Premier could care less. They are located at 205 complex dr, lakeland florida 33801. They obviously have a defective product and do not back it up for safety. My car was smoking and burning until I turned the switch off. I can not use it until it is replace, at my expense, not premier. I am furious that my family and I were subjected to a dangerous product. Premeir motor coach states they have never had any failure and blame the dealer. The dealer has been fair. I would like to also issue a consumer complaint with all necessary agencies. …
We bought this van as a conversion van. We have been very unhappy with the perofrmance of the van. We have had the airconditing repaired twice. The battery failed many times. One time the alternator was replaced. There has always been a clonking noise when braking that the dealer can identify. The tires wore out just after they were a year old. The van has also been taken to the dealer for numerous other repairs.( dot number: )
Frequently asked questions
Which Chevrolet Astro years have ac & heater problems?
By NHTSA complaints, the 1995 (13), 1996 (13), 1997 (13) and 1999 (6) model years. AC & Heater complaints make up 3% of all complaints for the 1995.
Is there a recall for Chevrolet Astro ac & heater problems?
No. NHTSA lists no a/c & heater recall for any Chevrolet Astro model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Chevrolet Astro ac & heater problems start?
Across all years, half of the complaints with a recorded mileage happened before about 103,000 miles; 14% happened before 50,000 miles.
What part fails most often?
Owners most often name the appliance › air conditioner (38 mentions), followed by the defroster/defogger/hvac system (10).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.