2004 Chevrolet Astro problems, complaints & recalls
Most-reported problem areas: Service Brakes, Hydraulic (3) · Service Brakes (2) · Visibility:glass, Side/Rear (1)
🧭 Reliability snapshot
Compared against other Chevrolet Astro model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (409)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Unknown Or Other 2025-07-18 · PIP5601C · Service Bulletin/Repair Instructions
this pi communicates the requirement to provide a pico file to receive diagnostic assistance from tac.
Unknown Or Other 2025-02-20 · PIP5358D · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. technician should get record a sound clip or take a video of the noise for assessment by engineering. technician will need to
Electrical System 2024-10-25 · PIP4723J · Service Bulletin/Repair Instructions
this preliminary information communicates to the dealer the process for downloading or updating operating software for the tire pressure monitor, active fuel injector tester, multi media tester, pico scope, gr8 starting/charging tester and vehicle data recorder tools, giving website address and ste
Unknown Or Other 2024-09-12 · PIT5099H · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about vehicles that the heater-vent-air conditioning blows warm air. before calling general motors technical assistance center technician will need to have high and low pressures, outside temperature, humidity, and ven
Unknown Or Other 2024-09-12 · PIT5099H · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about vehicles that the heater-vent-air conditioning blows warm air. before calling general motors technical assistance center technician will need to have high and low pressures, outside temperature, humidity, and ven
Unknown Or Other 2024-09-06 · PIT3271P · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about changing the tire and wheel size on vehicles. general motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. technician s
Showing the 6 most recent of 409 bulletins. Search all of them free at nhtsa.gov.
What owners report
2020-04-21 · Vehicle Speed Control · 70,000 mi“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, …”
2015-05-19 · Service Brakes · 50,500 mi“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. …”
2015-04-09 · Service Brakes“we live in the country with gravel roads. all of our chevrolet vehicles have had brake lines rot out. our ford and dodge vehicles have not. the chevrolet astro vans we have exhibit a propensity for the brake line rotting out over the gas tank as well as the brake lines over the front frame members. the brake lines on 20 year old ford vehicl…”
2014-06-20 · Fuel System, Gasoline:delivery:fuel Pump · 133,000 mi“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 man…”
2011-12-04 · Service Brakes, Hydraulic · 121,000 mi“ 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 ho…”
2011-04-17 · Service Brakes, Hydraulic · 86,000 mi“i have an '04 chevy astro van with ~ 88k miles. it is serviced every 3,000 miles. recently, my brakes failed. the cause was a worn brake line near the left front wheel. it had rubbed a hole it the line and i lost all the brake fluid. *tr…”
2011-03-31 · Suspension · 256,000 mi“as i was driving over some railroad tracks both of my front torsion bars failed and broke. had i been traveling on the interstate, it could have been fatal. from my online research, this same failure has happend to thousands of owners and no recall was done. gm even redesigned the torsion bars because of the known design flaws and it will cost w…”
2010-08-12 · Parking Brake · 131,193 mi“1. i parked my wife's van at the neighbor's house because guests were about to arrive. their driveway is on a slight incline so i engaged the emergency brake. 2. it occurred just once with the pedal going completely to the floor. 3. after contacting gm and being denied compensation due to no recall and the age of the vehicle i purchased and r…”
2010-02-04 · Service Brakes, Hydraulic · 126,000 mi · 🔥 fire“when my wife returned to our 2004 chevrolet astro van, the vehicle seemed to have a dead battery. the car would not turn over or fire the ignition. after having the battery and starter checked, we were told the battery was drained and they were able to charge the battery. the starter checked good. the car seemed to have a "dead short" when trying t…”
2008-10-14 · Air Bags:frontal · 68,000 mi · 💥 crash“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 seatbelt bruises. the van was not drivable and was towed…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.