VehicleVerdict

1991 Chevrolet Astro problems

Verdict · NHTSA data

Worth extra scrutiny

The 1991 Chevrolet Astro sits mid-pack among Astro years: 121 NHTSA complaints against a model median of roughly 95, with 6 recalls and 5 closed investigations. Complainants reported 11 injuries in total across these filings.

The trouble concentrates in one system: brakes issues account for 45% of all reports (54 of 121), far ahead of body & structure at 10.

121

NHTSA complaints

6

Recalls

5

Investigations

15

Crash-involved

5

Fires reported

11

Injuries

0

Deaths

NCAP overall

How does 1991 compare to other Astro years?

See all Astro years to avoid →

What are the most common 1991 Chevrolet Astro problems?

ComponentComplaintsShare
Brakes5445%
Electrical System108%
Body & Structure108%
Transmission76%
Seat Belts76%
Tires & Wheels54%
Steering54%
Seats43%
Latches & Locks32%
Climate Control (A/C & Heat)32%
Suspension32%
Engine22%
Other22%
Visibility & Wipers22%
Speed Control22%
Lighting22%

Does the 1991 Chevrolet Astro have recalls?

6 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E049000LightingMay 24, 2006 · 27,176 units

Defect

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE 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.

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

06E043000Fuel SystemMay 19, 2006 · 88,303 units

Defect

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.

Consequence

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.

Remedy

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).

06E026000LightingMarch 23, 2006 · 61,944 units

Defect

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.

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

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.

93V187000SeatsNovember 16, 1993 · 604,207 units

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.

91V164000Seat BeltsSeptember 20, 1991 · 4,842 units

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.

91V102000Seat BeltsJune 14, 1991 · 185 units

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

ABS: ANTI -LOCK BRAKE SYSTEM CAUSES BRAKE FAILURE, WHEN PUSHING DOWN ON PEDAL GOES DOWN HALF WAY, VEHICLE STOPS VERY SLOWLY AS IF HARDLY PUSHING BRAKES, AFTER FEW SECONDS, NORMAL BRAKE SYSTEM SEEMS TO KICK IN, VEHICLE COMES TO HALT, CAUSED ACCIDENT.*AK

Complaint filed with NHTSA · Brakes · May 15, 1996 · crash

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…

Complaint filed with NHTSA · Body & Structure · March 15, 2004

CAR PARKED IN DRIVEWAY. UPON TURNING KEY TO START, SMOKE STARTED BILLOWING FROM UNDER DASH. SHUT OFF KEY, DISCONNECTED BATTERY AND AIRED VEHICLE. FOUND MELTED/ BARE WIRING. CONTACTED CHEVERLOT CUSTORMER SERVICE (#990501Z66, CONTACT KIM HILL). INDIVIDUAL REPORTED NOTHING GM COULD DO TO DEFRAY COSTS…

Complaint filed with NHTSA · Electrical System · September 5, 1999 · fire

FOUR WHEEL DRIVE VEHICLE 'S DRIVESHAFT FLANGE DRILLED A HOLE THROUGH OIL FILTER CAUSING A FIRE AROUND THE FILTER AREA. TT

Complaint filed with NHTSA · Transmission · August 10, 1995 · fire

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

Complaint filed with NHTSA · Seat Belts · December 1, 2004

1991 Chevrolet Astro — common questions

Is the 1991 Chevrolet Astro reliable?

It is close to typical for the Astro: 121 NHTSA complaints, 6 recalls, and 5 investigations on file.

What are the most common 1991 Astro problems?

According to NHTSA complaint data, the leading problem areas are brakes (54 complaints), body & structure (10 complaints), electrical system (10 complaints).

Does the 1991 Chevrolet Astro have recalls?

Yes — NHTSA lists 6 recall campaigns affecting the 1991 Chevrolet Astro. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1991 Chevrolet Astro under NHTSA investigation?

NHTSA opened 5 investigations into this model year; all are now closed.

Which Chevrolet Astro years should you avoid?

Based on complaint rates and open investigations, the Astro years to avoid are 1995, 1997, 1994, 1996, 1998, 2000, 1999, 1993, 1992. The cleanest record among Astro years belongs to 1983.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.