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Research · Vans, Cargo Type

2004 Chevrolet AstroRecalls, problems, MPG & safety

NHTSA lists 2 safety recalls and 14 owner complaints for the 2004 Chevrolet Astro. Most complaints involve service brakes, hydraulic (4) and vehicle speed control (2). The EPA rates it 14–16 mpg combined.

Check a VINAdd to my garage
Combined MPG
14–16mpg
EPA · 6 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
2campaigns
Latest May 2006
Owner complaints
14
Top: service brakes, hydraulic
Fuel cost / yr
$3,900est.
EPA estimate, best version
01 —Recalls

Safety recalls

2 NHTSA campaigns · applies to some vehicles, check your VIN

Fuel system, gasoline

Free remedy

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.

Fuel system, gasolineReported May 19, 2006NHTSA 06E043000

Exterior lighting

Free remedy

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.

Exterior lightingReported Mar 23, 2006NHTSA 06E026000
Data from NHTSA Recalls API · synced Nov 9, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

14 complaints filed with NHTSA · Aug 2004 – Apr 2020
  1. Service brakes, hydraulic4
  2. Vehicle speed control2
  3. Service brakes2
  4. Electrical system2
  5. Fuel system, gasoline1
  6. Engine1
  7. Suspension1
  8. Parking brake1
  9. Air bags1

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each Astro model year we’ve synced.

View as table
Model yearNHTSA complaints
1996272
1997366
1998259
1999140
2000186
200196
200282
200389
200414
20059
Crashes reported
1
Fires reported
1
Injuries reported
3
Deaths reported
0
Data from NHTSA Complaints API · synced Nov 9, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Service brakes, hydraulic

4 reports1 fire
“IT STARTED WITH MY ABS BRAKE LIGHT COMING ON AND STAYING ON. THEN I STARTED TO ENCOUNTER ANTI LOCK PULSATIONS WHEN I SLOWED DOWN AND COMING TO A STOP, SOME TIMES I COULDN'T EVEN STOP WHEN & WHERE I WANTED. BRAKING DISTANCE STARTED BEING LONGER. THEN SOME TIME LATER I FELT AS THOUGH SOMEONE STUCK A BRICK UNDER MY BRAKE PEDAL BECAUSE NO MATTER HOW HARD I PRESS, I GUARANTEE YOU, I COULDN'T STOP. THANK GOD NO ONE WAS IN FRONT OF ME AS I CRUISED ON THOUGH THE STOP LIGHT! I WAS TOLD THAT MY ABS SENSORS WERE SLOWLY MALFUNCTIONING MOST LIKELY DUE TO CORROSION, A PROVEN DESIGN DEFECT. THEN MY ABS MODULE WILL GET SHORTED, AND THERE IS NO FAIL/SAFE WHEN IT GOES. I WAS TOLD THAT WHEN THE MODULE FAILS, HANG ON BECAUSE I WILL CRASH. THIS SCARES ME TO DEATH AND I WONT LET ANYBODY DRIVE MY VAN IN CASE THIS HAPPENS WHEN THEY ARE DRIVING. ALSO WHEN WE WANT TO TAKE A TRIP I DON'T WANT TO TAKE MY VAN BECAUSE I'M AFRAID 6 TO 8 PEOPLE COULD GET HURT AND IT WOULD BE ON ME. EVERY REASON I BOUGHT THIS AWD VAN IS COMPLETELY OUT THE WINDOW. I CANT SELL IT BECAUSE OF THE BRAKE PROBLEM. I'M STUCK WITH A VAN THAT I CANT USE. I'M WRITING THIS BECAUSE WHEN I WENT TO GET THE ABS SERVICED I…”
Owner complaint to NHTSAFiled Dec 4, 2011Service brakes, hydraulicODI 10438527

Vehicle speed control

2 reports
“ONCE OR TWICE PER YEAR WHEN USING CRUISE CONTROL, WHEN I TOUCH BRAKE TO DEACTIVATE CRUISE, IT DOESN'T DISENGAGE. I THEN HAVE TO STAND ON BRAKE WITH ALL MY EFFORT TO STOP VAN AND PULL OVER TO PUT IN PARK. ENGINE CONTINUES RACING TIL I TURN KEY OFF. THEN EVERYTHING OK TIL NEXT TIME MAYBE MONTHS LATER. SWITCK ON BRAKE PETAL IS OK. ONCE IN THE WINTER, CRUISE CONTROL PUSHED ME INTO AN INTERSECTION. LUCKILY OTHER TRAFFIC REALIZED I COULDN'T STOP. NO CODES SHOW UP TO IDENTIFY CAUSE. BEEN DOING THIS 4 OR 5 YEARS INTERMITTENTLY. EVEN THO THIS VAN IS 16 YEARS OLD, IT ONLY 6HAS 90000 MILES ON IT. I TRY NOT TO DRIVE IT MUCH BECAUSE OF THIS PROBLEM. MY BEST GUESS IT'S MECHANICAL OR COMPUTER PROBLEM BUT SINCE IT HAPPENS SO SELDOM HARD TO DIAGNOSE.I HAVE ANOTHER ASTRO 5 YR OLDER WITH 230000 ON IT AND CRUISE WORKS LIKE IT SHOULD. I HAVE NO MORE INFORMATION.”
Owner complaint to NHTSAFiled Apr 21, 2020Vehicle speed controlODI 11321778

Service brakes

2 reports
“ANTILOCK BRAKING SYSTEM WARNING LIGHTS AND BRAKE LIGHT CAME ON WHEN I WAS ENTERING THE FREEWAY. THE LIGHTS CONTINUE TO COME ON WHENEVER I AM DRIVING. I HAD IT CHECKED AT CORNING CHEVROLET AND WAS TOLD THE PART ALONE WAS $900 PLUS LABOR TO REPLACE IT. THE BRAKES WORK, BUT NOT THE ANTILOCK SYSTEM INSTALLED BY THE MANUFACTURER.”
Owner complaint to NHTSAFiled May 19, 2015Service brakesODI 10717422
All 2004 Astro problemsSend a problem to a mechanic on findmechanic.ai
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 9, 2026
04 —Key specs

Engines, transmissions & drive

6 versions rated by the EPA
EPA class
Vans, Cargo Type, Vans, Passenger Type
Engines
4.3L 6-cyl
Transmissions
Automatic 4-spd
Drive
Rear-Wheel Drive · 4-Wheel or All-Wheel Drive
Fuel
Regular Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Nov 9, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
Astro 2WD (cargo)
Auto 4-spd, 6 cyl, 4.3 L · Rear-Wheel Drive
141916$3,900555
Astro 2WD (passenger)
Auto 4-spd, 6 cyl, 4.3 L · Rear-Wheel Drive
141916$3,900555
Astro 2WD (cargo) Conversion
Auto 4-spd, 6 cyl, 4.3 L · Rear-Wheel Drive
141815$4,150592
Astro AWD (cargo)
Auto 4-spd, 6 cyl, 4.3 L · 4-Wheel or All-Wheel Drive
141815$4,150592
Astro AWD (cargo) Conversion
Auto 4-spd, 6 cyl, 4.3 L · 4-Wheel or All-Wheel Drive
121614$4,450635
Astro AWD (passenger)
Auto 4-spd, 6 cyl, 4.3 L · 4-Wheel or All-Wheel Drive
121614$4,450635
Estimate your fuel costCost of ownership
Data from EPA fueleconomy.gov · synced Nov 9, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

1 tested variant
NHTSA has not published 5-Star Safety Ratings for the 2004 Chevrolet Astro as of Nov 9, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Nov 9, 2026Vehicle 1052
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

2004 Astro questions

How many recalls does the 2004 Chevrolet Astro have?

2 safety recalls as of Nov 9, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 2004 Chevrolet Astro problems?

Owners filed 14 complaints with NHTSA. The most-cited components are service brakes, hydraulic (4), vehicle speed control (2), service brakes (2). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 2004 Chevrolet Astro get?

The EPA rates the 2004 Chevrolet Astro at 14–16 mpg combined, depending on engine and drivetrain (6 versions rated).

Data from NHTSA & EPA · synced Nov 9, 2026