The 1991 Chevrolet Astro has 3 NHTSA recall campaigns affecting an estimated 609,234 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 121 complaints with NHTSA, most often about the service brakes, hydraulic. Last updated July 5, 2026.
Recall campaigns
SEATS93V1870001993-11-16604,207 affected
Defect
THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL BETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEADS TO JOINT LOOSENESS, CAUSING BOLT FATIGUE AND EVENTUAL BOLT FAILURE.
Consequence
IF BOLT FAILURE OCCURS TO THE DRIVER'S SEAT, IT WOULDALLOW THE SEAT BACK TO SUDDENLY RECLINE, AND COULD RESULT IN LOSS OF VEHICLECONTROL AND A VEHICLE CRASH WITHOUT PRIOR WARNING.
Remedy
DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT FRAME "SOFT" JOINT AND REPLACE THE RECLINER BOLTS.
SEAT BELTS91V1640001991-09-204,842 affected
Defect
SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.
Consequence
VEHICLES WOULD NOT COMPLY WITH FMVSS 210.
Remedy
REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.
SEAT BELTS91V1020001991-06-14185 affected
Defect
THE SEAT BELTS FOR THE FRONT AND MID-SHIP SEATS DID NOT REST ON PELVIS AS REQUIRED BY FMVSS 209.
Consequence
SEAT BELTS MAY NOT RESTRAIN SEAT OCCUPANT, AND COULDINJURE THE SEAT OCCUPANT IN THE EVENT OF A SUDDEN STOP OR ACCIDENT.
Remedy
RELOCATE SEAT BELT ANCHOR BOLTS TO ADJUST BELTS FOR SEAT LOCATIONS.
Complaints by component
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
40
7crashes1injuries
STRUCTURE:BODY:DOOR
7
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH
5
4fires
SEAT BELTS:FRONT:RETRACTOR
4
2crashes3injuries
EQUIPMENT:APPLIANCE:AIR CONDITIONER
3
POWER TRAIN:DRIVELINE:DRIVESHAFT
3
1fires
SEAT BELTS:FRONT:WEBBING
3
1crashes4injuries
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT
3
STEERING: STEERING WHEEL/HANDLE BAR
3
TIRES:TREAD/BELT
3
Total complaints121
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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…”
“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”
“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”
“Driver's side and passenger's side front and rear seat belt retractor failed to click in and hold. This problem occurred more than once and had not been resolved. Consumer contacted dealer on numerous occasions, but nothing was resolved. *ak *tc”
“Consumer stated while driving pins in steering column sheared, causing steering to drop. Consumer had to pull to the side of the road and call a tow truck. Consumer had vehicle towed to his home, and repaired the problem himself. Also, door handles broke off, all almost at the same time, within a…”
“Consumer stated while driving pins in steering column sheared, causing steering to drop. Consumer had to pull to the side of the road and call a tow truck. Consumer had vehicle towed to his home, and repaired the problem himself. Also, door handles broke off, all almost at the same time, within a…”
“Repeated total failure of brake system resulting in three separate rear end accidents over 13 year period. Original owner. When braking for sudden emaergency stop,after initial braking begins, brake petal goes down to floor and brakes completely release, resulting in no brake stoppage of vechicle…”
“Paint peeling off truck all over”
Defect investigations
InvestigationDP92012 Opened 1992-06-09 · closed 1992-06-25
APV FIRES
APV FIRES
InvestigationEA91028 Opened 1991-06-10 · closed 1992-06-30
BRAKE FAILURE
===
InvestigationEA92022 Opened 1992-06-24 · closed 1993-11-19
SEAT BACK BOLT BREAKAGE
There is no summary currently available
InvestigationPE91052 Opened 1991-02-22 · closed 1991-06-10
BRAKE FAILURE
There is no summary currently available
InvestigationPE97025 Opened 1997-06-12 · closed 1997-11-26
INSTRUMENT PANEL/DASH ELECTRICAL FIRE
ALLEGED ELECTRICAL FIRES MAY OCCUR IN THE DASH AREA WHILE THE SUBJECT VEHICLES ARE BEING OPERATED OR WHILE PARKED.
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Chevrolet Astro as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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