Problems owners report
Complaints filed with NHTSA about the 1991 Chevrolet Astro, by the system named in each complaint. One complaint can name several.
- Service brakes, hydraulic42
- Structure10
- Electrical system8
- Seat belts7
- Steering5
- Power train5
- Tires4
- Seats3
- Latches/locks/linkages3
- Suspension3
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 10 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
In New Zealand
1 1991 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Recalls in Canada
4 Transport Canada recalls for the 1991 Chevrolet Astro.
| 2000080 21 Mar 2000 | Accessories On certain vehicles operated in areas of high salt use, the spare tire hoist cable may corrode and eventually break. This would allow the spare tire to fall of… |
| 1993153 15 Nov 1993 | Seats And Restraints ON VEHICLES EQUIPPED WITH BUCKET SEATS WITH KNOB TYPE RECLINER MECHANISMS, A FRONT SEAT RECLINER BOLT MAY FATIGUE AND BREAK. THIS MAY ALLOW THE SEAT BACK TO SUD… |
| 1993120 20 Aug 1993 | Brakes On certain K1500, Astro, Safari and Suburban vehicles, corrosion of the composite front brake rotors could cause separation of the stamped steel centre section … |
| 1991175 23 Dec 1991 | Brakes On certain vehicles, In areas of high road salt use, corrosion of the composite front brake rotors could cause separation of the stamped steel centre section fr… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL BETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEADS TO JOINT LOOSENESS, CAUSING BOLT FATIGUE AND EVENTUAL BOLT FAILURE.
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
THE SEAT BELTS FOR THE FRONT AND MID-SHIP SEATS DID NOT REST ON PELVIS AS REQUIRED BY FMVSS 209.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Chevrolet told its dealers about the 1991 Chevrolet Astro: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 634999 | DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT |
| 41063 | RECALL 91-C-50 - GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 CHEVRTOLET C/K TRUCKS, M/L AND G VANS EQUIPPED WITH 4.3L ENGINES [RPO LB4 OR RPO LU2 (M VAN ONLY)] MAY BE EMITTING NON-METHANE HYDROCARBONS (NMHC) IN EXCESS OF CALIFORNIA EMISSIONS STANDARDS. CALIFORNIA EMISSIONS STANDARDS WERE ESTABLISHED TO PROTECT THE PUBLIC HEALTH AND WEALFARE FROM DANGERS OF AIR POLLUTION. EXCESS EMISSION OF NMHC MAY CAUSE A VEHICLE TO FAIL STATE MANDATED EMISSION TESTS. TO CORRECT THIS CONDITION, DEALERS ARE TO INSTALL A NEW OXYGEN SENSOR. *TW |
| 39304 | COLD ENGINE KNOCK. *TW |
| 38076 | CALIFORNIA RECALL - GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 C/K TRUCKS, M/L AND G VANS WITH 4.3L ENGINES MAY BE EMITTING NON-METHANE HYDROCARBONS IN EXCESS OF CALIFORNIA EMISSION STANDARDS. TO CORRECT THIS CONDITION, DEALERS ARE TO INSTALL A NEW EXHAUST OXYGEN SENSOR. *TW |
| 37947 | OIL PRESSURE GAUGE READING CONCERNS. *TW |
| 37942 | TRANSMISSION EXTENTION SEAL LEAKS. *TW |
| 10028790 | GENERAL MOTORS: ON ALL 1988-2009 FULL SIZE CHEVROLET/GMC PICKUPS, UTILITIES AND VANS, THE BRAKE PEDAL WILL MOVE DOWN OR SELF APPLY DURING FULL LOCK TURNS OR NEAR FULL LOCK TURNS. CHEVROLET ASTRO AND GMC SAFARI VANS; HUMMER 2 ARE INCLUDED. *PE UPDATED 5/24/11. *PE |
| 10007838 | DIAGNOSTIC INFORMATION FOR INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP, BUSY/CYCLING TCC OR NOISY COOLING FAN. *TT |
| 10007244 | WINDOW REGULATOR MOTOR DOES NOT FIT. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
INSTRUMENT PANEL/DASH ELECTRICAL FIRE
SEAT BACK BOLT BREAKAGE
APV FIRES
BRAKE FAILURE
BRAKE FAILURE
NHTSA Office of Defects Investigation