1990-2004 Chevrolet Astro Full Review - Consumer Guide Automotive

Our in-depth review covers everything you need to know about this generation Chevrolet Astro. Get the latest news, find a local dealer, and get a free price quote for this generation Chevrolet Astro.

1990-2004 Chevrolet Astro Review

Introduced for 1985, Chevrolet's rear-drive minivan and its GMC Safari counterpart are taller, tougher, and more trucklike than Dodge/Plymouth rivals (which are front drive). A properly equipped Astro could haul up to 6000 pounds. Five-passenger seating was standard, but Astros could be equipped to hold up to eight occupants. Starting in 1990, antilock brakes acted on all four wheels (front-disc/rear-drum). Full-time 4-wheel drive also arrived as an option for 1990. An extended-length body was added during the model year, with ten inches tacked onto the rear for nearly 19 extra cubic feet of cargo capacity.

Year to Year Changes

1991 Chevrolet Astro: A more powerful, high-output V6 became available in 2WD models during '91. All outboard seats now had lap/shoulder belts.

1992 Chevrolet Astro: Still another high-output engine joined the Astro option list. This one developed 200 horsepower. A new "Dutch" rear-door option featured a one-piece glass liftgate with separately opening split panel doors below.

1993 Chevrolet Astro: Astro's 4-speed automatic transmission gained electronic shift controls, plus a second-gear start feature for improved slippery-surface traction. The base engine gained 15 horsepower, and speedometers now were calibrated to 100 mph instead of 85.

1994 Chevrolet Astro: The driver-side airbag became standard in all Astros. Side-door guard beams went into front doors and the sliding side door, while a center high-mounted stoplamp was installed in the roof.

1995 Chevrolet Astro: Facelifted with a new grille and nose for 1995, all models now came with extended bodies and a 190-horsepower engine. CL and LT option groups featured new composite headlamps and body-colored fascias.

1996 Chevrolet Astro: A passenger-side airbag went into Astros for 1996, along with a new dashboard that contained rotary controls and a locking glovebox. Horsepower remained at 190 but torque dropped by ten pound-feet, peaking at lower rpm than before. New spark plugs were said to last 100,000 miles. A new engine cover increased front foot room and contained molded-in cupholders.

1997 Chevrolet Astro: Speed-sensitive power steering and daytime running lights went into the '97 Astro. Optional leather upholstery became available later in the model year.

1998 Chevrolet Astro: Astro gets only exterior color changes and a revised transmission for '98.

1999 Chevrolet Astro: Astro's all-wheel-drive system was revised so that power was only sent to the front wheels when needed for maximum traction. Other changes included a standard overhead console on LS and LT trimmed models.

2000 Chevrolet Astro: Eight-passenger seating became standard this year, so no more 5-passenger models were available. A 7-passenger setup with two second-row buckets remained as an option. Chevrolet claimed that internal changes made the Astro's engine quieter and smoother for 2000. A Tow/Haul mode was added for more-efficient shifting when carrying heavy loads. New standard features included headlamps that switch on automatically in low-light conditions, a larger fuel tank made of plastic instead of metal, and retained accessory power that permits operating electrical accessories for up to 20 minutes after shutting off the ignition.

2001 Chevrolet Astro: A tilt steering wheel, cruise control, CD player, remote keyless entry, and power windows, mirrors and locks were newly standard in 2001.

2002 Chevrolet Astro: Cargo models offered remote keyless entry and a rear heater for 2002.

2003 Chevrolet Astro: The standard antilock brakes are upgraded to an all-disc setup and wheels are increased by one inch to 16-inches on all models.

2004 Chevrolet Astro: There were no significant changes made in 04.

1990-2004 Chevrolet Astro Road Test

Pros	Cons

Antilock brakes	Fuel economy

Optional AWD traction	Entry/exit

Passenger and cargo room	Ride

Trailer-towing capability

Consumer Guide® Road-Test Evaluation

Spacious inside, Astro vans can be fitted to tow up to three tons and seat up to eight. The penalty that must be paid for its brawn is a rough, bouncy ride--definitely less carlike than front-drive minivans, which serve as replacements for the traditional old family station wagon. Clumsy handling also ranks as subpar. Even the least-potent V6 engine has plenty of torque for hauling heavy loads and towing, but that muscle does not translate into brisk acceleration. As for economy, we averaged just 14.5 mpg in an early AWD, regular-length Astro. Expect around 15 mpg in urban driving, and not a whole lot more on the highway. Another demerit: Servicing isn't so easy. Entry/exit to the front seats is hampered by doorways that are narrow at the bottom. There's also a tall step-up to get inside. Interiors offer loads of passenger and cargo room, though front-seat riders must deal with uncomfortably narrow footwells. The dashboard, as revised for 1996, has a convenient layout with plenty of built-in storage space. With eight seats, a regular-length Astro has little rear cargo room. All-wheel drive offers better rain/snow traction, but with even more thirst for gas. It also makes the Astro an inch higher, adding to step-in height.

Value for the Money
Like the now-extinct Ford Aerostar, the Astro and its GMC Safari cousin are truck-based vehicles, better suited to heavy-duty work than are front-drive minivans. Trucklike behavior could be a turnoff unless you need Astro's brand of brawniness for towing or other demanding applications.

Consumer Guide® Road Test Ratings

Chevrolet Astro 2WD LS	Rating

Performance	4

Fuel Economy	3

Ride Quality	3

Steering/Handling/Braking	3

Quietness	3

Controls/Materials	6

Interior Room	3

Room/Comfort (rear)	6

Cargo Capacity	10

Value within Class	4

Total:	45

Each vehicle report contains one rating chart for representative model. Consumer Guide® rates in ten key areas: Performance, Fuel Economy, Ride Comfort, Steering and Handling, Interior Noise, Controls and Materials, Driver Room, Passenger Room, Cargo Capacity, and Insurance Costs. These ratings compare the particular vehicle rated to ALL other vehicles, not a vehicle's standing in a particular class. In the ratings table, "1" is the lowest rating and "10" is the highest rating.

1990-2004 Chevrolet Astro Reliability

Trouble Spots

Consumer Guide's® Auto Editors have scoured repair bulletins and questioned mechanics to search for commonly occurring problems for a particular vehicle. In some cases we also give possible manufacturer-suggested solutions. In many instances these trouble spots are Technical Service Bulletins posted by the manufacturer, however, we have our own expert looking at additional vehicle problems.

Doors: Improper adjustment of the sliding door can make it hard to open or close. (1990-93)

Engine knock: A knocking sound may be due to three possible causes and may be fixed with either an oil filter having a built-in check valve, a revised PROM or replacement of the main bearings. (1990-95)

Engine misfire: New valve-guide seals should eliminate the blue smoke from the tailpipe during cold starting. (1990-93)

Engine misfire: The fuel injector wires tend to get pinched when the air filter is reinstalled. (1990-93)

Engine noise: An engine noise might be caused by the exhaust valves sticking in their guides. New valve-guide seals should correct the problem if the guides are not worn. (1996)

Engine temperature: Overheating and coolant loss may be due to rough surface on radiator filler neck. Neck should be sanded smooth and cap replaced. (1999-2000)

Transmission leak: The rear seal on the transmission (extension housing seal) may leak on vans with a one-piece drive shaft. (1990-94)

Transmission leak: Fluid may leak from the pump body on 4L60-E transmissions due to the pump bushing walking out of the valve body. (1995-96)

Consumer Guide® Estimated Repair Costs

This table lists costs of likely repairs for comparison with other vehicles. The dollar amount includes the cost of the part(s) and labor (based on $50 per hour) for the typical repair without extras or add-ons. Like the pricing information, replacement costs can vary widely depending on region. Expect charges at a new-car dealership to be slightly higher.


Item Name	Repair Cost

A/C Compressor	$515

Alternator	$245

Automatic Transmission or Transaxle	$770

Brakes	$225

Clutch, Pressure Plate, Bearing	$555

Exhaust System	$320

Radiator	$420

Shocks and/or Struts	$247

Timing Chain or Belt	$255

Universal Joints	$153

NHTSA Recall History

1990-91: Bucket seat's knob-type recliner mechanism with foam or vinyl "soft joint" may loosen and cause bolt failure, allowing seatback to recline suddenly; could produce loss of control.

1992-94: Front seatbacks do not conform to height requirements.

1994: Airbag-advisory labels may be missing.

1995 w/L35 engine: Fuel lines at tank were improperly tightened and could loosen, allowing leakage and possible fire.

1995: On a few vans, left lower control-arm bolt could loosen, fatigue, and break.

1995-97: The windshield-wiper motor may fail on certain vehicles. Dealer will inspect and replace affected parts.

1996-97: Outboard-seatbelt webbing on right-rear bucket seat can separate during crash.

1996-98 w/integrated child seats: Seatbelt-retractor clutch spring and/or pawl spring in child seat may be missing.

1998: On certain vehicles, the outside rearview mirror switch may short circuit. Dealer will inspect and replace affected parts.

1999: Audible fasten-seatbelt warning may not sound or may not sound as long as is required by the standard.

2001-02: Multifunction switch may develop an open circuit, causing stop lamps and hazard lamps to become inoperative.

2003: Poorly manufactured steering knuckles on some vehicles may allow for road contamination to enter and wear down the ball joint, resulting in difficulty controlling the vehicle

1990-2004 Chevrolet Astro Prices

Prices	Good	Average	Poor

1990
Astro 2WD	$1,000-1,500	$600-900	$100-200
Astro AWD	$1,200-1,700	$700-1,000	$100-200

1991
Astro 2WD	$1,100-1,600	$700-1,000	$100-200
Astro AWD	$1,400-1,900	$900-1,200	$200

1992
Astro 2WD	$1,200-1,800	$700-1,100	$100-200
Astro AWD	$1,500-2,100	$1,000-1,400	$200-300

1993
Astro 2WD	$1,400-2,100	$900-1,300	$200-300
Astro AWD	$1,700-2,400	$1,100-1,600	$300-400

1994
Astro 2WD	$1,600-2,400	$1,100-1,600	$200-300
Astro AWD	$2,000-2,800	$1,400-2,000	$300-500

1995
Astro 2WD	$1,900-2,700	$1,300-1,900	$300-400
Astro AWD	$2,300-3,000	$1,700-2,200	$400-600

1996
Astro 2WD	$2,300-3,400	$1,700-2,400	$400-600
Astro AWD	$2,700-3,700	$2,000-2,800	$600-800

1997
Astro 2WD	$2,800-3,900	$2,100-2,900	$600-900
Astro AWD	$3,200-4,200	$2,500-3,300	$800-1,100

1998
Astro 2WD	$3,300-4,300	$2,600-3,400	$800-1,100
Astro AWD	$3,700-4,700	$3,000-3,800	$1,100-1,400

1999
Astro 2WD	$3,900-5,000	$3,200-4,100	$1,200-1,600
Astro AWD	$4,300-5,500	$3,600-4,600	$1,500-1,900

2000
Astro 2WD	$4,700-5,800	$3,900-4,900	$1,800-2,200
Astro AWD	$5,200-6,300	$4,400-5,400	$2,100-2,500

2001
Astro 2WD	$5,500-6,500	$4,700-5,600	$2,300-2,700
Astro AWD	$6,000-7,000	$5,200-6,100	$2,500-2,900

2002
Astro 2WD	$6,700-7,700	$5,900-6,800	$3,100-3,500
Astro AWD	$7,200-8,200	$6,400-7,300	$3,500-4,000

2003
Astro 2WD	$8,000-9,500	$7,200-8,600	$4,100-4,800
Astro AWD	$8,500-10,000	$7,700-9,000	$4,400-5,200

2004
Astro 2WD	$9,800-11,300	$8,800-10,200	$5,100-5,900
Astro AWD	$10,400-12,000	$9,400-10,800	$5,500-6,400

This chart details a range of prices in year-by-year listings for vehicles in three condition levels:

Good: a clean low-mileage, solid-running vehicle that needs little or no repair.

Average: a car with normal miles on the odometer, perhaps a few scrapes or dings; engine might need a minor repair or two, but runs acceptably well.

Poor: might have potentially dangerous problems with the engine and/or body, or abnormally high mileage; definitely in need of mechanical attention. Valuations reflect wholesale prices paid by dealers at auction, and retail prices on used-car lots. Each range covers all trim levels and engine types for a vehicle with a typical amount of equipment--usually an automatic transmission, air conditioning, stereo, etc. Fully loaded vehicles may cost more. Average mileage is 12,000 miles per year. Keep in mind that these are guidelines only. Actual selling prices vary- especially from region to region.

1990-2004 Chevrolet Astro Specs & Safety

Vehicle Dimensions

Specification	1990-94 3-door van

Wheelbase, in.	111.0

Overall Length, in.	176.8

Overall Width, in.	77.5

Overall Height, in.	76.2

Curb Weight, lbs.	3897

Cargo Volume, cu. ft.	151.8

Standard Payload, lbs.	--

Fuel Capacity, gals.	27.0

Seating Capacity	8

Front Head Room, in.	39.2

Max. Front Leg Room, in.	41.6

Rear Head Room, in.	37.9

Max. Rear Leg Room, in.	36.5

Specifications Key: NA = not available; "--" = measurement does not exist.

Powertrain Options and Availability

In all Astros, a 4.3-liter V6 engine hooks to a 4-speed automatic transmission. The standard engine in 1990 was rated 150 horsepower, but an optional 175-horsepower edition joined during the '91 model year. A year later, the optional HP (High Performance) V6 put out 200 horsepower, available only in 2WD models. Base-engine horsepower rose from 150 to 165 in 1993. For 1996, the V6 became part of GM's Vortec family, reaching 190 horsepower but dropping from 260 to 250 pound-feet of torque.

Engines	Size liters / cu. in	Horse- power	Torque	Transmission: EPA city/hgwy	Consumer Guide Observed

ohv V6	4.3 / 262	150-165	230-235	4-speed automatic: 16/21	4-speed automatic: 14.5

ohv V6	4.3 / 262	175-200	250-260	4-speed automatic: 16/20	4-speed automatic: 15

Specifications Key: NA = not available; "--" = measurement does not exist.

NHTSA Crash-Test Results

Test	1999 Astro

Front Impact, Driver	3

Front Impact, Passenger	4

The National Highway Traffic Safety Administration (NHTSA) tests a vehicle's worthiness in front- and side-impact collisions and rates its resistance to rollovers. Front-impact crash-test numbers indicate the chance of serious injury: 5 = 10% or less; 4 = 10-20%; 3 = 20-35%; 2 = 35-45%; 1 = More than 45%. Side-impact crash-test numbers indicate: 5 = 5% or less; 4 = 6-10%; 3 = 11-20%; 2 = 21-25%; 1 = More than 26%. Rollover resistance numbers indicate the chance for rollover when the vehicle leaves the roadway: 5 = Less than 10%; 4 = 10-20%; 3 = 20-30%; 2 = 30-40%; 1 = More than 40%.

Built In: USA

Drive Wheels: longitudinal front-engine/rear- or all-wheel drive

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Also in the 1990-2004 Chevrolet Astro Review:

Chevrolet Astro

Chevrolet Astro Road Test

Chevrolet Astro Reliability

Chevrolet Astro Prices

Chevrolet Astro Specs & Safety

Chevrolet Astro Photos

Chevrolet Astro Full Review