Engine complaints by model year
Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
What owners report
On September 9, 2005 my 2003 Chevrolet Astro van exploded and caught fire in a parking lot. The fire dept. Arrived and put out the fire; the firemen disconnected the battery cable. The van was towed to huffines Chevrolet in plano, tx. The cause of the incident according to the Chevrolet mechanics is as follows: 1) every time the steering wheel was turned, the tie rods etc. Would chafe against a bracket on the chassis that held down a battery cable. 2) eventually the bracket failed. 3) the battery cable arced against the brake line. 4) the brake line ruptured spraying hydraulic fluid over the hot engine manifold. 5) the ensuing fire burned through, among other things, the A/C hose carrying freon. 6) when the A/C hosed was severed, the freon gas escaped causing the loud explosion that we heard some distance away. 7) the smoke that we saw in the air was actually the escaping freon gas. …
After ball joint recall, I have had nothing but problems with steering, braking and suspension. Front left side continually pops and grinds, shock boot was replaced twice, the shocks have been replaced 3 times. The third time May have fixed it, just got the van back today. Brakes are intermittent. Heard loud bang from rear end, dealership tightened backing plate. Transmission slips, shudder is felt from rear end at 30+ MPH. Dealership put balances on torque converter and the drive shaft, had to cut the rear springs to do this. Service manager stated the problem was not gone, but livable. Vehicle runs rough at idle, almost stalling, service manager experienced the problem as well. Said fuel injector port was fill with carbon, but cleaning it did not fix the problem. …
When the vehicle was started in the morning, the brakes made a grinding noise when depressed. The vehicle was serviced by the dealership twice and they replaced the brake disc, rotors and shoes. While driving down a hill with the brake pedal depressed, the brake system overheated, and a burning odor filled the cabin of the vehicle. The brakes started to pulsate again while going down a mountain, a noise was heard coming from the driveline between shifts and was unable to be duplicated, the transmission slipped and shifted erratically, the engine would break up on a slight acceleration due to the distributor cap and the rotor being corroded.
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. This was not the case as the same problem happened two additional times (October 24, 2004 and December 16, 2004) with the same terrifying consequences with on coming traffic. I was fortunate not to be killed or kill someone else with this vehicle stalling in on coming traffic.
2001 Astro van Chevy panic stop brakes no response to floor 1st. Time had looked at pass. Side wear 1 side brake pad wear repair. 2nd time need to stop fast hit brakes to floor no response both 35 MPH to 45 MPH called GM acted like don't care . Turn signal switch replace 710.00 will not reimburse engine light on and off replace sensors $275.00 catalytic converter $1000.00 then motor failure dealer could not pin point problem new motor 6538.00 bought van from dealer said o.k. For 150000 to 200000 had 47000 now 130000 will not buy g.m.
I have had a miss when vehicle is warm. Dealer says it is fuel, but I am using the recommended fuel according to dealer. The check engine light comes on and then goes off. Dealer cannot locate problem. This is an ongoing issue since I have purchased it. Also had to replace front brake pads and shocks at 26000 miles. After approximately one year use.
Vehicle stalls when traveling! Almost crashed with children in vehicle because of complete operational failure! Vehicle restarts, however May stall at any time! I took vehicle to attendant shop as well as a Chevy shop and they both failed to find the cause. This is extremely dangerous and the problem must be dealt with accordingly.
Dt: the check engine light comes on and off. The ABS system activates while driving on the highway. Also, the ABS light comes on. It does this off and on by itself. This started on August 1, 2005. There is a recall, Chevrolet is still recalling, but not sure at this time if consumer's vehicle is included.
Frequently asked questions
Which Chevrolet Astro years have engine problems?
By NHTSA complaints, the 1997 (38), 1995 (29), 1998 (28), 1996 (18) and 2000 (17) model years. Engine complaints make up 11% of all complaints for the 1997.
Is there a recall for Chevrolet Astro engine problems?
No. NHTSA lists no engine & cooling 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 engine problems start?
Across all years, half of the complaints with a recorded mileage happened before about 87,000 miles; 19% happened before 50,000 miles.
What part fails most often?
Owners most often name the engine › gasoline (50 mentions), followed by the engine (33).
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.