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Vehicle safety record

2002 Chevrolet Astro Problems, complaints & recalls

Owners have filed 82 complaints about the 2002 Chevrolet Astro with NHTSA, most often about the brakes (27) and the electrical system (17). Those complaints describe 9 crashes, 3 fires, 5 injuries and 4 deaths. It is covered by 3 recalls, the latest in May 2006 for the fuel system, gasoline. For comparison, the 2001 has 96 and the 2003 has 89.

NHTSA data checked

CAbout as many problems as a typical Astro year, for its age

#128 most complained-about 2002 vehicle

Complaints
82
Recalls
3
Crashes
9
Fires
3
Injuries
5
Deaths
4

Most common 2002 Chevrolet Astro problems

Share of all 82 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.

2002 Chevrolet Astro recalls 3

Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do

Fuel system

06E04300088,303 vehicles affected

The problem
Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from october 18, 2005, through march 21, 2006, sold for use on the vehicles listed above and on certain school buses. (To see the school bus engine sizes, click on "document search" and then "bus applications"). The connector on the fuel filter was not manufactured to honeywell's specification. As a result, the o-ring may not seat correctly on the fuel line.
The risk
This condition may cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
The fix
Honeywell will notify owners and replace the fuel filters free of charge. The recall began on october 18, 2006. Owners may contact fram customer service at 1-800-890-2075 (option 1).

Exterior lighting

06E02600061,944 vehicles affected

The problem
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. Some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, Lamps, reflective devices, and associated equipment.
The risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
The fix
Pro-a motors will notify owners and offer to repurchase the lamps. The recall began on april 3, 2006. Owners may contact pro-a motors at 323-838-2988.

Exterior lighting: switch

05V09900077,055 vehicles affected

The problem
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.
The risk
The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash.
The fix
Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module free of charge. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The recall began on april 13, 2005. Owners may contact chevrolet at 1-800-630-2438 or gmc at 1-866-996-9463.

What owners say

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82 complaints about the 2002 Chevrolet Astro

Newest first, as filed with NHTSA by owners. Page 1 of 4.

Acceleration & cruise control

The contact owns a 2002 Chevrolet Astro. The contact stated that while driving at an undetermined speed, the accelerator throttle cable fractured in the stuck open position, causing the vehicle to accelerate to approximately 100 MPH independently. There were no warning lights illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and notified of the failure. The approximate failure mileage was 258,300.

Filed Incident Vehicle speed controlNHTSA 11490984
Wheels & tires

Goodyear viva 3 tires suffered stone punctures. Tire size 215/75r15. Bought two new ones 10/5/16 and two more new ones 3/7/17. This vehicle is infrequently driven and only occasionally on county maintained gravel roads. Only drove 18300 miles before first stone puncture 9/27/20. Second stone puncture occurred with only 12/17/20 with 15800 miles on that tire. Third stone puncture occurred 1/17/20 with 16200 miles. Dot number md36jk1r4116 for tires bought 13/7/17. Dot number md36jk1r1216 for tires bought 10/5/16.

Filed Incident TiresNHTSA 11388928
Airbags

While vehicle was being driven.The alert warning light for the air bags illuminated. I was afraid to drive the vehicle due too the air bag inflator might rupture or underinflate. In the event of a crash. An underinflated air bag may not properly protect the occupant. This scenario increases the risk of serious injury or death.

Filed Incident Air bagsNHTSA 11365408
Electrical systemVisibility & wipers

When raining widshield wipers dont work as directed, they do what they want. They stay on after shutting them off. And door locks lock and unlock repeatedly. Wipers also shut off in the middle of line of sifht intermittently. Never works correctly

Filed Incident Electrical system · Visibility / wiperNHTSA 11012920
Lights

Tl* the contact owns a 2002 chevrolet astro. The contact stated that on several occasions, the brake lights and hazard lights failed. The contact stated that if the brake pedal was depressed and the hazard light switch was moved around the lights would function as intended. The vehicle was not taken to be diagnosed or repaired. The vehicle was not included in nhtsa campaign number: 05v099000 (exterior lighting). The manufacturer was notified of the failure. The failure mileage was not available. Updated 07/13/16*lj the consumer stated the brake lights only worked, if the hazard light switch was forced to one side and held in place. Updated 07/13/16.*Jb

Filed Incident Exterior lightingNHTSA 10871748
Brakes

I got in my van to drive to a store and the brake pedal went right to the floor. There was brake fluid leaking from near the rear tire. The steel hard brake line running from the abs unit to the rear axle is rusted through and is leaking. This was a sudden event. Also the fuel lines look to be just as bad. I'm sure stainless steel lines would not have added much to the vehicles cost and would have prevented this hazard and expense. *Tr

Filed Incident Service brakesNHTSA 10706501
Seats & seat belts

Tl* the contact owns a 2002 chevrolet astro. The contact stated that the driver's side seat belt webbing failed to lock and was able to be pulled from the housing. The failure recurred multiple times. The manufacturer was not made aware of the failure. The failure mileage was 325,000.

Filed Incident Seat beltsNHTSA 10678995
SteeringElectrical systemDriver assistance

I was driving and all of a sudden, the dash lights went out and the car died. I lost power steering, and I coasted to the side of the road. Come to find out the fuse box was hot and there was a few fuses that were blown. I replace the blown fuses and drove home. When I got home and turned off the van, I couldn't get it start I looked at the same fuse and they were blown again. The van now sits in the driveway till I figure this out. Because it is too dangerous to drive. *Tr

Filed Incident Steering · Electrical system · Electronic stability control (ESC)NHTSA 10619259
Wheels & tires

Tl* the contact owns a 2002 chevrolet astro equipped with gremax max 5000 tires (n/a), size 215/75r15 and the dot was jehkdvp2312. The contact stated that while traveling 40 mph, the front passenger side tire blew out. The manufacturer was not notified of the failure. The tire and vehicle failure mileage was 142,057.

Filed Incident TiresNHTSA 10585974
Electrical systemBrakes

Vehicle lost all electrical power to every system that is controlled by the ignition being turned on. Driver was in the process of making a u-turn around a curbing island in the divided traffic road when all electrical was interrupted while the steering wheel was turned all the way to the left. Condition caused steering to become difficult, brake pedal went clear to the floor, air conditioning and radio and headlights all went off. Condition was repeatable with exception of brake pedal, each time steering was...

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turned to the left. Inspection under vehicle found that main power cable is routed across front side of main frame motor mount member. There was a slight curve in the way the wire was routed and each time the steering was turned to the left, the inner tie rod end for the right wheel came in contact with the wire harness. After many miles, the protective cover and then the actual wire insulation was rubbed through. This caused a direct short to ground through the steering parts of all (switched while running) electrical components of the vehicle. Problem was corrected by taping the wire insulation, then taping the protective covering. I then had to fabricate a bracket to screw to the steel crumple member to hold the harness back from the steering linkage. *Tr

Filed Incident Electrical system · Service brakesNHTSA 10546973
Electrical systemVisibility & wipersEquipment & accessories

Recently I took my van to a dealer because the knob on the a/c fan melted off it cost 600 dlrs in repairs the hvac knob had melted off also the connector and resistor had burned out . The entire wiring harness was melted together. No fuse blew to prevent his form happening we are not sure what caused this to occur. My concern is that this could have caused a fire in the dash while I was driving resulting in severe injury accident or even death. Please contact me if there was a recall I missed or if there is any information as to why this happened. Thank you for your time concern chevy owner. *Tr

Filed Incident Electrical system · Visibility · Equipment adaptive / mobilityNHTSA 10470766
Brakes

Abs was activated at slow speeds causing a substantial drop in braking power. *Tr

Filed Incident Service brakesNHTSA 10468081
Electrical systemFire

Tl* the contact owns a 2002 chevrolet astro van. The contact stated when the vehicle was shifted into park she noticed there was smoke and fire behind the steering wheel. There was also a minor explosion. The fire department was notified and stated that an electrical wire started the fire. A report was filed and the failure was not diagnosed nor towed from the contacts residence. The manufacturer was not notified. The failure and the current mileage was 170,000. Updated 8/23/12

Filed Incident Electrical systemNHTSA 10458535
BrakesElectrical systemDriver assistance

Abs coming on at very low speeds on dry pavement (under 5mph/8kmh). It doesn't do it every time, but quite often at low speeds, like coming to a red light, stop sign or parking. Of course, there is no need for the abs come on at such low speeds and especially not on dry pavement. *Tr

Filed Incident Service brakes, hydraulic · Electrical system · Electronic stability control (ESC)NHTSA 10432683
Brakes

Tl* the contact owns a 2002 chevrolet astro. The contact stated that the front brake lines were rusted. The abs unit was not working properly and the rear brakes had already failed. The vehicle was not inspected by the dealer but was repaired by the contact. The current mileage was 79,000 and the failure mileage was unknown.

Filed Incident Service brakes, hydraulicNHTSA 10432394
Electrical system

I have a 02'chevy impala when I turn it on all electric comes on and the engine runs for a split second and dies then the battery light and service traction system comes on I got the fuel pump and sensor replaced still the same problem occurs. I was able to drive it for a few miles after reading the manual and pushing the gas to the floor while holding the keys on for three seconds but eventually it died again. Please help!!!!! *Tr

Filed Incident Electrical systemNHTSA 10353924
Electrical system

This is a general point of information message: for the last decade or more, gm vehicles have a propensity to burn out their lamps due to an overcharge condition (cause unknown to me); this condition can affect any of the lamps or bulbs, most noticably headlamps, tail lights, and running (parking) lamps. Could you please investigate this electrical defect in all gm vehicles.*Tr

Filed Incident Electrical systemNHTSA 10331354
Brakes

Tl* the contact owns a 2002 chevrolet astro van. When driving at low speeds the anti-lock braking system would activate without warning, increasing the vehicle's stopping distance. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 76,000. Updated 5/12/10 *cn updated 06/18/10.*Jb

Filed Incident Service brakes, hydraulicNHTSA 10319196
SteeringBrakes

Tl*the contact owns a 2002 chevrolet astro van. The contact stated that while driving in reserve at approximately 5 mph, the brakes and the power steering malfunctioned. The vehicle was towed to a local mechanic. The mechanic could not remedy the problem. The contact stated that the vehicle was unsafe to drive. The failure mileage was 25,000.

Filed Incident Steering · Service brakes, hydraulicNHTSA 10315519
Acceleration & cruise control

Tl*the contact owns a 2002 chevrolet astro van. While driving 30 to 35 mph, the vehicle began accelerating on its own. The vehicle would not slow down by applying the brakes which forced the contact to shift gears into neutral and then into third gear. Within a few minutes, the contact was able to slow down the vehicle engaging the brake pedal and shut the engine off. The contact was informed to engage the accelerator pedal to loosen the throttle; however, when he restarted the vehicle the rpm's increased...

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rapidly. The police helped the contact push the vehicle onto the emergency lane. The vehicle was towed to the dealer. The dealer stated that the rapid acceleration was due to a frayed accelerator cable. The dealer replaced the accelerator cable and adjusted the idle and throttle plate. The vehicle is driving normally. The contact requested the parts from the dealer who stated that they were not longer available. The contact is concerned about the safety risk since a crash could have occurred. The failure mileage was 172,777.

Filed Incident Vehicle speed controlNHTSA 10299850
Lights

Hazard lights stop working and causes the trailer lights not to work( no left turn, right turn or brakes to trailer harness). Signals and brakes on van works okay but no hazards. *Tr

Filed Incident Exterior lightingNHTSA 10264251
BrakesCrash1 injury

Tl. Contact owns a 2002 chevy astro van. Current mileage was 97,000 and failure mileage were 50,000. Contact stated upon purchasing the vehicle from enterprise car rental the brakes have been bad. Contact stated that the vehicle has been in the shop over 20 time most of the time for the brakes. Contact has crash the due to the brakes on the vehicle. Contact feels thatthe vehicle was a lemon upon purchase and does not feel this vehicle should be on the road. Jo

Filed Incident Service brakes, hydraulicNHTSA 10259849
SteeringBody, doors & structure

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. *Tr

Filed Incident Steering · StructureNHTSA 10258210
Body, doors & structure

Back door handle broke off the van cannot get in the back of the 2002 astro van. *Tr

Filed Incident StructureNHTSA 10255266
BrakesCrash

On march 26, 2008, I took my 2002 chevy astro van to be serviced. Mileage 93,829,i had no brakes. The master cylinder was determined to be the cause of the failure and was replaced. On april 12, 2008, once again I had no brakes, this time it resulted in me getting into and accident. I took the van back to the same repair shop. When they put it on the lift they said the whole braking system was melted until the point of the hose bursting. He said he never saw anything like this in his 20 years of service. They did...

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not want to touch it stating it was now a liability to them and directed me to chevy. Chevy concurred, four different people said they have never seen or have a clue at what caused this. They called in gm, who also never had seen this, but bounced the blame on a questionably installed master cylinder. Chevy said they can replace the whole braking system because they do not know what is wrong, but since they do not know what caused this or why fuses didn't blow to prevent it, it could happen again. We hired our own car consultant to look at the van, he too has never seen or heard of anything like this. The heat and melted brake lines ran closer than 1/4 inch away from the gas tank. I do not want to take the risk of driving again with my children and loosing brakes or possibly igniting the gas tank. *Tr

Filed Incident Service brakes, hydraulicNHTSA 10248363

Chevrolet Astro: every year compared

YearComplaintsRecallsCrashesFiresTop problemGrade
20059210Wheels & tiresA
200414211BrakesA
200389343BrakesC
200282393BrakesC
2001963101BrakesC
20001862274BrakesD
19991404182BrakesD
19982596237Visibility & wipersF
All Astro years

2002 Chevrolet Astro vs rivals

More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.

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Questions about the 2002 Chevrolet Astro

Does the 2002 Chevrolet Astro have any recalls?

Yes - NHTSA lists 3 recalls for the 2002 Chevrolet Astro: fuel system, gasoline (May 2006); exterior lighting (March 2006); switch (March 2005). Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.

What are the most common problems with the 2002 Chevrolet Astro?

By the complaints owners filed with NHTSA, the most common problem areas are the brakes (27), electrical system (17), steering (9).

How many complaints has the 2002 Chevrolet Astro had?

82 complaints have been filed with NHTSA, the first on April 16, 2002 and the latest on October 26, 2022. Of these, 9 describe a crash and 3 a fire, and together they report 5 injuries and 4 deaths.

Is the 2002 Chevrolet Astro a reliable vehicle?

Its Safety Index is 43 out of 100 (grade C: about as many problems as a typical Chevrolet Astro year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.

Which Chevrolet Astro years have the most complaints?
What should I do if my 2002 Chevrolet Astro has a problem?

If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.

Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data

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