Image By: Harvey Henkelman
The 4.3L V6 engines in these vans are nearly bullet proof. There is a reason they have been in production from 1985 in Chevrolet/GMC C/K trucks all the way to 2014 placed in the Silverado and Sierra. With routine maintenance, these engines can last close to 400k miles.
Although the Astro and Safari are built from a tried-and-true drivetrain, there are still issues that may arise in both the AWD models and the 2wd models.
I will be going over the main issues that may arise to better educate you about your purchase or your ride and hopefully save you from some headache on trying to figure out these issues.
Let us get started!
Door locks
The door lock actuators fail, which is typical. When I got my Astro van, I had to replace all 4 actuators. I would not recommend getting the cheapest one on amazon but get a name brand actuator. Trust me. Link to them will be down below.
Rear AC
The rear AC can prematurely fail due to a leak in the rear ac lines. What most people do is remove the entire unit, plug the lines, recharge the system, and cover the hole in the floor. I will be plugging my ac lines in a few weeks. Or you could trace the leak and fix it. Most likely it is the seal between the lines and the unit itself.
Rear brakes not illuminating
Rear brake lights not working, specifically in the 2002 model but others as well. If the hazards are also malfunctioning, then its most likely due to a short and replacing the multi-function lever will fix that issue. You will need a reverse torx head socket set for this job, so be prepared with the correct tools.
Worn front suspension
High mileage AWD models will develop a severe pull to one side during braking, most likely due to a broken ball joint or control arm.
No start due to a failed Fuel pump. If the fuel filter is not routinely replaced, then expect the fuel pump to go out. I have a video you can check out on creating an access door to the fuel pump, or you could lower the tank and replace the fuel pump. Be sure to replace the fuel filter as well.
Oil Pan in AWD models
Worn engine mounts in the AWD model causing damage to the oil pan. These are hard to replace in the AWD vehicles, so patience and research is virtue.
Rusty brake lines
In the north, it is common for the brake lines to rust out. So, keep an eye on that. You can purchase a set of new brake lines to replace them.
Arm rest on door panel
Cracking on the driver and passenger arm rest. You can get an armrest cover to fix this issue, which is simply glued on, but it does look factory.
Hard to get to Spark Plugs
The easy task of replacing sparkplugs is actually hard in these vans due to the placement of the engine. You will need special extensions and tools to get them all. With the proper technique, it can be easy.
Distributor Issue
Pancake Distributor Disease, yes you heard that right. Usually shows a P03000 code or no code at all. It is basically a random misfire in the engine that’s directly correlated to the distributors gear being made of soft materials. If left untreated, you can potentially clog up your catalytic converters due to the unburnt fuel and cause your ignition coils to fail. I have a link to a distributor that will not fail down below.
Transmission fluid
Replacing the transmission fluid can be proven to be somewhat difficult and should be done routinely, about every 30k miles and 15k miles if you tow stuff. You must remove the entire oil pan and tip it one way to remove most of the fluid, then lower it. Also, you should change out the filter, which can also be hard due to the gasket. I will have a video on the process soon and ill post it in the description down below. You can buy an oil pan with a drain bolt if you would like to make your job easier in the future. Also link down below.
Leaking barn door in rear
Leaking door from the rear Dutch door. Now, there are not many true solutions besides upgrading the weather seals around the door or be like this dude and add a piece of metal to stop the rain from entering.
Do not do that. It was a joke.
Power Steering Pump
Finally, the power steering pump likes to fail and its actually not very hard to replace.
Conclusion
Overall, the Chevrolet Astro is a very reliable vehicle. Tackle the common faults right away, you will not have many issues. I am actually building one into a budget friendly camper van, which is why I already have videos on the van, so check them out if you are interested. If you are in the market for a cargo van, or just a reliable daily driver that can meet almost all your needs, even with decent gas mileage, this is the way to go. If I missed an issue, let me know in the comments! I am human and we all miss things.
If you are tired of ready, watch this instead: