Problems · NHTSA complaints

2004 Chevrolet Astro problems

Owners filed 14 complaints about the 2004 Chevrolet Astro with NHTSA between Aug 2004 and Apr 2020. The most-cited component is service brakes, hydraulic (4).

Complaints
14
Filed with NHTSA
Crashes
1
Reported by owners
Fires
1
Reported by owners
Injuries
3
People reported injured
Deaths
0
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  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
  10. Latches/locks/linkages1
  11. Visibility1

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

Data from NHTSA Complaints API · synced Nov 9, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
20041
20051
20061
20071
20081
20090
20102
20113
20120
20130
20141
20152
20160
20170
20180
20190
20201

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

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

Electrical system

2 reports1 fire
“TL* THE CONTACT OWNS A 2004 CHEVROLET ASTRO. THE CONTACT STATED THAT THE VEHICLE FAILED TO START UNTIL AFTER THREE ATTEMPTS. THE CONTACT SHIFTED INTO DRIVE AND THEN THE VEHICLE LOST ALL POWER. THE CONTACT PUMPED THE ACCELERATOR PEDAL, WAITED TEN MINUTES AND THE VEHICLE RESUMED ITS NORMAL OPERATION. THE FAILURE OCCURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE DEALER DIAGNOSED THE FAILURE AND STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE DEALER ASSURED THE CONTACT THAT AFTER PAYING FOR THE REPAIR, THE FAILURE WOULD BE RESOLVED. THE FUEL PUMP, STARTER, MOTOR MOUNTS, AND GENERATOR WERE ALL REPLACED; HOWEVER, THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 133,000. THE CURRENT MILEAGE WAS 134,249.”
Owner complaint to NHTSAFiled Jun 20, 2014Fuel system, gasoline, Electrical system, EngineODI 10604713

Fuel system, gasoline

1 report1 related recall

Engine

1 report
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 9, 2026

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