1991 Chevrolet Astro problems & reliability
95 owner complaints filed with NHTSA for the 1991 Chevrolet Astro. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
6 complaints report injuries (10 injured).
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Service Brakes, Hydraulic → | 42 | 44% |
| Structure → | 10 | 11% |
| Electrical System | 8 | 8% |
| Seat Belts | 7 | 7% |
| Power Train | 5 | 5% |
| Steering | 5 | 5% |
| Tires | 4 | 4% |
| Equipment | 3 | 3% |
| Latches/locks/linkages | 3 | 3% |
| Seats | 3 | 3% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Complaints by incident year
What owners report
“Beginning about a year ago, have had intermittent hard pedal when braking. Occurs rarely, without warning. No abs light seen but suspect possible abs malfunction. Pedal does not pulsate but a faint growling, grinding, or buzzing noise is heard. May be abs motor cycling. During failure brakes are barely operative…”
Service Brakes · filed Dec 2, 2019
“The door handles on both the passenger and driver side broke off. The sliding side door lock engaged before the door fully closed breaking the locking mechanism. I have seen several astro as well as safari vans with missing handles. I am having trouble finding replacement doors. *tr”
Structure · filed Jan 31, 2009
“The driver's side seat belt retractor failed to retract on its own. The driver was able to contact the dealer for appointment. Please fill in additional information. *jb”
Seat Belts · filed Jan 14, 2005
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- INSTRUMENT PANEL/DASH ELECTRICAL FIRE
Preliminary Evaluation PE97025 · opened Jun 12, 1997 · closed Nov 26, 1997
- SEAT BACK BOLT BREAKAGE
Engineering Analysis EA92022 · opened Jun 24, 1992 · closed Nov 19, 1993 · led to recall 93V187000
- APV FIRES
Defect Petition DP92012 · opened Jun 9, 1992 · closed Jun 25, 1992
- BRAKE FAILURE
Engineering Analysis EA91028 · opened Jun 10, 1991 · closed Jun 30, 1992
- BRAKE FAILURE
Preliminary Evaluation PE91052 · opened Feb 22, 1991 · closed Jun 10, 1991
Technical service bulletins
9 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 1991 Chevrolet Astro.
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…
PIT-3665-A · Service Bulletin/Repair Instructions · issued Nov 1, 2010
Diagnosis of cracked or broken transmission case. *tt 2006 and prior cars and light duty trucks. *tt
020730024A · Service Bulletin/Repair Instructions · issued Aug 1, 2005
Window regulator motor does not fit. *tt
01667 · Service Bulletin/Repair Instructions · issued Jan 1, 2004
Diagnostic information for intermittent transmission downshift, slip, busy/cycling tcc or noisy cooling fan. *tt
990730016A · Service Bulletin/Repair Instructions · issued Oct 1, 2002
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…
RCL/91C50 · Service Bulletin/Repair Instructions · issued Apr 1, 1995
COLD ENGINE KNOCK. *TW
376105 · Service Bulletin/Repair Instructions · issued Feb 1, 1995
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…
RCL/91C50 · Service Bulletin/Repair Instructions · issued Feb 1, 1995
Oil pressure gauge reading concerns. *tw
476149 · Service Bulletin/Repair Instructions · issued Dec 1, 1994
Transmission extention seal leaks. *tw
467108 · Service Bulletin/Repair Instructions · issued Dec 1, 1994
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
No NHTSA recall campaigns name the 1991 Chevrolet Astro in our current data. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 1991 Chevrolet Astro?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.