Body complaints by model year
Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
What owners report
While driving at 5 MPH consumer attempted to park in the driveway and without warning lost steering ability. Also, brakes were inoperable, and would not stop the vehicle. The vehicle collided with the outside wall of the garage. There was considerable damage to the garage and the vehicle. Consumer sustained no bodily injuries. Sliding door doesn't unlock to open. Dealer replaced ps pump because pump drive shaft was broken, and reinstalled side door.
2002 Chevy Astro van idler arm pulled through the frame of the front right portion resulting in partial steering failure on February 1, 2009. Upon inspection by halleen Chevrolet service department it was determined that not only had the front right idler arm broken through the frame but the front left idler arm was also in danger of breaking through. This would result in complete steering failure. The service department at the dealership determined that the vehicle needed a complete frame replacement.
While driving at any speed and without warning there is a constant noise coming from gear box. Dealer has been notified, and mechanic stated there was a chatter in the gear box, problem has been inspected by dealer, however was unable to correct the problem.*akthe dealer replaced the pressure line in the steering, power steering fluid was leaking,the turn signal was not cancelling when making right turns, left rear cargo door would not stay open.
Sliding passenger door no longer comes with a manual release for the open position. If the van is backed nose down on a hill the door will not stay open. Someone has to hold it. The friction plate can be tightened but that will eventually cause failure as that wear.
Door handle on right rear dutch door of our 2000 Astro van broke suddenly when trying to open door. While the dutch door feature is operationally very handy, the door design always had a flimsy feel to it - so we always used great care when opening and closing. After it broke, we found the NHTSA #634576 with similar complaints, so felt obligated to add to your list.
While driving the vehicle would surge and jerk then clunk, the dealer has attempted to repair the vehicle several time but the problem resurfaces, other failures include PCM failed causing the check engine light to illuminate, the gas gauge jumps from full tank to empty causing the vehicle to run out of gas, rear door handle broke twice, drivers side window motor was replaced and the air bag light would flicker on and off.
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.
Vehicle in for service. Mechanic left vehicle running & shut doors. Vehicle caught on fire in door area & locked it. Broke window to enter & put flames out. No work being done on door at time of flames. Mechanic will check for cause of fire.
Frequently asked questions
Which Chevrolet Astro years have body problems?
By NHTSA complaints, the 1997 (32), 1995 (20), 1996 (15), 2000 (15) and 1998 (8) model years. Body complaints make up 9% of all complaints for the 1997.
Is there a recall for Chevrolet Astro body problems?
No. NHTSA lists no body & structure 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 body problems start?
Across all years, half of the complaints with a recorded mileage happened before about 79,000 miles; 28% happened before 50,000 miles.
What part fails most often?
Owners most often name the body › door (60 mentions), followed by the body › door › hinge and attachments (14).
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.