2004 Chevrolet Astro problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 17 complaints on file for the 2004 Chevrolet Astro — too few to judge reliability from owner reports alone — but 2 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

NHTSA complaints

Recalls

Investigations

Crash-involved

Fires reported

Injuries

Deaths

—

NCAP overall

How does 2004 compare to other Astro years?

Astro NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Astro years to avoid →

What are the most common 2004 Chevrolet Astro problems?

Component	Complaints	Share	vs prior year
Brakes	7	41%	▼ down
Speed Control	2	12%	— flat
Electrical System	2	12%	▼ down
Latches & Locks	1	6%	▼ down
Suspension	1	6%	▼ down
Airbags	1	6%	— flat
Visibility & Wipers	1	6%	▼ down
Engine	1	6%	▼ down
Fuel System	1	6%	▼ down

Does the 2004 Chevrolet Astro have recalls?

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

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.

Consumer complaints filed with NHTSA

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

“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…”
Complaint filed with NHTSA · Brakes · May 18, 2006

“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.…”
Complaint filed with NHTSA · Electrical System · June 14, 2013

“DT: WITHOUT WARNING THE CRUISE CONTROL WILL SHUT OFF WHEN THE CONSUMER HITS A BUMP. THE CONSUMER DOESN'T KNOW WHEN IT'S GOING TO HAPPEN. THE DEALER WAS UNWILLING TO TROUBLESHOOT, BECAUSE THE MANUFACTURER WILL NOT REIMBURSE THEM FOR THE COST. THE MANUFACTURER WILL NOT PAY TO HAVE TEST RUN ON CAR.…”
Complaint filed with NHTSA · Speed Control · April 4, 2005

“MY WIFE WAS DRIVING A 2004 CHEVY ASTRO VAN APPROX. 35-40 MPH ON A TWO-WAY STREET. ANOTHER DRIVER FROM THE OPPOSITE DIRECTION CUT ACROSS INTO HER LANE AND HAD A HEAD-ON COLLISION. SHE SUFFERED A BROKEN WRIST & BRUISED RIBS. SHE HAD THREE OF OUR CHILDREN IN THEIR SEATS. THEY WERE SHAKEN AND HAD…”
Complaint filed with NHTSA · Airbags · October 10, 2008 · crash

“ REAR DRIVER SIDE WINDOW EXPLODED AND THE GLASS COMPLETELY SHATTERED, WITHOUT BEING STRUCK WITH AN OBJECT. VEHICLE WAS PARKED AND TURNED OFF WHEN THIS OCCURRED. DEALERSHIP WAS CONTACTED. NO INJURIES WERE SUSTAINED BECAUSE THE SEAT WAS NOT OCCUPIED AT THE TIME OF THE INCIDENT.*AK”
Complaint filed with NHTSA · Visibility & Wipers · August 10, 2004

2004 Chevrolet Astro — common questions

Is the 2004 Chevrolet Astro reliable?

The record is thin — 17 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 2 recalls should be verified as completed.

What are the most common 2004 Astro problems?

According to NHTSA complaint data, the leading problem areas are brakes (7 complaints), electrical system (2 complaints), speed control (2 complaints).

Does the 2004 Chevrolet Astro have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Chevrolet Astro. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

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.

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

Compiled by Sharon Ben-Moshe, Founder.

How does 2004 compare to other Astro years?

What are the most common 2004 Chevrolet Astro problems?

Does the 2004 Chevrolet Astro have recalls?

Consumer complaints filed with NHTSA

2004 Chevrolet Astro — common questions

Is the 2004 Chevrolet Astro reliable?

What are the most common 2004 Astro problems?

Does the 2004 Chevrolet Astro have recalls?

Which Chevrolet Astro years should you avoid?

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