Problems owners report
Complaints filed with NHTSA about the 2002 Chevrolet Astro, by the system named in each complaint. One complaint can name several.
- Service brakes, hydraulic20
- Electrical system13
- Seat belts8
- Steering7
- Structure5
- Tires5
- Vehicle speed control5
- Power train5
- Visibility4
- Air bags4
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 4 injuries and 4 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fuel consumption
Official Canadian test results for 4 variants: combined 14.4–15.6 L/100 km (about 15–16 mpg US), CO₂ 331–359 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Astro Cargo · Van: Cargo · Regular gasoline | 16.3 | 12.1 | 14.4 |
| Astro Passenger · Van: Passenger · Regular gasoline | 17.0 | 12.8 | 15.1 |
| Astro Cargo AWD · Van: Cargo · Regular gasoline | 17.3 | 12.8 | 15.3 |
| Astro Passenger AWD · Van: Passenger · Regular gasoline | 18.1 | 12.6 | 15.6 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
1 Transport Canada recall for the 2002 Chevrolet Astro.
| 2005061 10 Mar 2005 | Electrical On certain vehicles, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and h… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
05V099000 · Exterior lighting14 Mar 2005 · 77,055 vehicles
ON CERTAIN MINIVANS, THE MULTIFUNCTION SWITCH MAY DEVELOP AN OPEN CIRCUIT CONDITION IN THE STOP LAMP OR HAZARD LAMP CIRCUIT THAT RESULTS IN THE STOP LAMPS AND HAZARD LAMPS BEING INOPERATIVE.
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 2002 Chevrolet Astro: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 637186 | THE SUBJECT OF THIS SERVICE VOICEMAIL IS FOR THE VEHICLE THEFT DETERRENT, VTD, LEARN PROCEDURE. *TT |
| 634999 | DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT |
| 634915 | SUBJECT REGARDING EXCESSIVE NOISE FROM POWER STEERING SYSTEM WHILE TURNING OR UNDER LIGHT BRAKING. *TT |
| 634576 | SOME CUSTOMERS MAY COMMENT THAT THE RIGHT REAR DOOR HANDLE ON THE CARGO DOOR BREAKS. *TT |
| 629755 | SUBJECT REGARDING REPORTS OF WAVY OR A RIPPLED APPEARANCE OF THE ROOF PANEL. *TT |
| 628934 | SOME CUSTOMERS MAY COMMENT THAT THE SERVICE ENGINE SOON LAMP IS ILLUMINATED, NO 3RD AND 4TH GEAR, THE TRANSMISSION DOES NOT SHIFT CORRECTLY, THE TRANSMISSION FEELS LIKE IT SHIFTS TO NEUTRAL OR A LOSS OF DRIVE OCCURS. *TT |
| 628815 | SUBJECT REGARDING DIAGNOSTIC TIPS FOR SLIPPING OR MISSING SECOND, THIRD AND/OR FOURTH GEAR. *TT |
| 628059 | CUSTOMERS MAY COMMENT ABOUT POOR RADIO RECEPTION. *TT |
| 628035 | CUSTOMERS MAY COMMENT ABOUT A LACK OF HEAT. *TT |
| 627912 | SERVICE ENGINE SOON LAMP ILLUMINATED, INCORRECT TRANSMISSION SHIFTS, POOR PERFORMANCE OF ENGINE, TRANSMISSION SLIPPING. *YH |
| 626527 | CUSTOMERS MAY COMPLAIN OF WHAT APPEARS TO BE A WATER LEAK IN THE WINDSHIELD AREA. *JG |
| 625097 | INFORMATION REGARDING UPPER BODY APPEARANCE CHANGES AT THE WINDOW OPENING AREAS OF ALL PASSENGER VANS. *YH |
| 609703 | A BOOM NOISE INSIDE THE VEHICLE WHILE DRIVING AT SPEEDS RANGING BETWEEN 97 - 105 KM/H (60 - 65 MPH). *TT THIS BULLETIN IS REVISED AND REPLACED BULLETIN 00-03-09-001 DATED 01/01/2000. *TT UPDATED *EH |
| 11009156 | This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update. |
| 11007744 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007743 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11006621 | Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers. |
| 11006421 | GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return. |
| 11004761 | This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 11004557 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 11002312 | This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information. |
| 10252735 | This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish. |
| 10252163 | XM Audio Traffic And Travel Link Availability And Operation. |
| 10251890 | This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 10250775 | This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system. |
NHTSA manufacturer communications (public domain)
NHTSA investigations
PE04072 · Exterior lighting:brake lightsopened 19 Oct 2004 · closed 21 Mar 2005
LOSS OF BRAKE LAMP ILLUMINATION
NHTSA Office of Defects Investigation