The Chevrolet Astro (Chevy Astro or GMC Safari) is a mid-sized van made from 1985-2005. The Astro/Safari have a cult following due to their mid-size and available AWD.
Specifications
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Alternator
See this thread on upgrading The Big Three.
All wheel drive
“ Past '96 (I think) they're all e-clutch t-cases, but they all swap easily to the venerable NP/NV241 found in anything from Jeeps to Cummins RAMs to Silverados.[1] ”
“ If you get one you should drain the transfer case fluid and replace it with Dextron-III as there was a service notice from Chevy about this. It originally came with something else in it which would cause binding at low speeds and cause shuddering when turning.[2] ”
Known issues
- steering knuckles that cut ball joint boots[3]
- door handles break off
- 1998-1999 particularly hard hit by transmission valve body failures [4] "Less common problems are the failures of the transmission's fluid pressure (TFP) switch, failure of the transmission's "reaction sun shell" and failure of the transfer case shift motor."
- power locks fail: "grease them once a year with lithium spray in grease. The rear door lock may be fixed by drilling a hole through the piece of zinc to repair the piece that broke off."[5]
- power windows fail - switch failure?
- ABS controller failure
- rough idle or misfires: "problems with the spark plugs, ignition systems and poor vacuum seals have been implicated in some cases"[6] "Get a good [distributor] cap with brass contacts."
- idler/pitman arm failure
- transmission output seal failures
- intake manifold gasket leaking oil or coolant
- 1984-early 1985 models may have oil pressure idiot light incorrectly wired to CHOKE indicator
- fuel pump failure – earlier than normal fuel filter changes may help alleviate
- P1870 This can be caused by wear of the bore for the TCC isolator and regulator valves in the valve body.
- alternator failures
- plastic radiator tank leaks[7]
