Astro AWD "Stroverlander"

[ihatemybike]

Catching up.The Astro is looking sweet.It's hard to find AWD Astros and fullsize vans.

Weather is too nice by you to make the AWD a popular option.

I only found 21 within 500 miles of you.

Found 185 nationwide

Prices are getting low on them so many turn up on Craigslist

I plan on buying my next one from the Southwest, probably take a week of vacation just to get it.

 

[Stroverlander]

Weather is too nice by you to make the AWD a popular option.

I only found 21 within 500 miles of you.

Great, now I'll be looking at vans for the next hour plus!

I found mine two years old with 35k in Chicago, put a deposit down with the dealer and flew up to drive her home. I figured two years in the rust belt wouldn't affect the chassis too much and it didn't.

I see there is a rare black 2005 AWD in that link which was my first preference at the time though now I really like the metallic grey. Looks like a decent van, only 77k, it has G80 option but it's a GU6 3.42 ratio and it has rear heat, rear a/c, even BFG A/Ts.

I wonder if it was only the tow package option vans that came with GT4 3.73 gears unless specifically ordered that way?

If I didn't have my van, I might be all over that. Would cover it with matte paint protection film and would be nasty looking!

If anyone is interested, can use http://www.compnine.com/vid.php to decode option list with vin.

 

[digitaldelay]

Looks like a decent van, only 77k, it has G80 option but it's a GU6 3.42 ratio and it has rear heat, rear a/c, even BFG A/Ts.

I agree, nice van but someone in VA please go remove that nasty hitch cover! :sombrero:

Jason

 

[Stroverlander]

:iagree: Thank you for not adding the image here.

 

[Expedition_Bound]

 

[ben2go]

Great, now I'll be looking at vans for the next hour plus!

I found mine two years old with 35k in Chicago, put a deposit down with the dealer and flew up to driver her home. I figured two years in the rust belt wouldn't affect the chassis too much and it didn't.

I see there is a rare black 2005 AWD in that link which was my first preference at the time though now I really like the metallic grey. Looks like a decent van, only 77k, it has G80 option but it's a GU6 3.42 ratio and it has rear heat, rear a/c, even BFG A/Ts.

I wonder if it was only the tow package option vans that came with GT4 3.73 gears unless specifically ordered that way?

If I didn't have my van, I might be all over that. Would cover it with matte paint protection film and would be nasty looking!

If anyone is interested, can use http://www.compnine.com/vid.php to decode option list with vin.

Thats the thing.None are really close to me.At least not close enough to make it worth the trip to check out.

 

[Stroverlander]

Being on the Gulf Coast, I really didn't have much choice except to search nationally.

 

[ihatemybike]

The GT4 option happened most often in mountainous states. I had a 2000 AWD w/ tow package and it was GU6.

ben2go, you could check out the 2WD Astros near you to get your mind going, then find an AWD away from you and have it inspected by a shop not related to the sale before heading out to purchase.

That's my plan for my next AWD, as I don't want anything that lived in the rust belt.

 

[ben2go]

I have driven quite a few Astros.I like them for the most part.Just hard to find a AWD and one in good condition is even rarer.

 

[driver3]

Great, now I'll be looking at vans for the next hour plus!

I found mine two years old with 35k in Chicago, put a deposit down with the dealer and flew up to driver her home. I figured two years in the rust belt wouldn't affect the chassis too much and it didn't.

I see there is a rare black 2005 AWD in that link which was my first preference at the time though now I really like the metallic grey. Looks like a decent van, only 77k, it has G80 option but it's a GU6 3.42 ratio and it has rear heat, rear a/c, even BFG A/Ts.

I wonder if it was only the tow package option vans that came with GT4 3.73 gears unless specifically ordered that way?

If I didn't have my van, I might be all over that. Would cover it with matte paint protection film and would be nasty looking!

If anyone is interested, can use http://www.compnine.com/vid.php to decode option list with vin.

So, if you were to do it again, is there a different van you would like to start with? I'd love to do this, but I'm far from pulling the trigger. I live in CO and drive 20k+ miles a year. We are in the mountains every weekend and an awd van would be awesome for what I do. My last two cars have been an H3 with the adventure package and now a bmw xi wagon. SUV was good, but no room, and the bmw actually has more room and more mpg, but not off road at all (obviously). This seems like a really fun option, but I did see some welding on page 2 or 3 that has put me off a bit. I can work on a lot myself, but wouldn't be able to pull that off.

Here's one near me that looks great --> http://denver.craigslist.org/ctd/3610224143.html

So, is there a specific build, year, mileage, that would be best here? Ultimately I'm looking for the ability to do the 31 inch tires and eventually a full time 4x4 option.

Thanks!

 

[Stroverlander]

So, if you were to do it again, is there a different van you would like to start with? I'd love to do this, but I'm far from pulling the trigger. I live in CO and drive 20k+ miles a year. We are in the mountains every weekend and an awd van would be awesome for what I do. My last two cars have been an H3 with the adventure package and now a bmw xi wagon. SUV was good, but no room, and the bmw actually has more room and more mpg, but not off road at all (obviously). This seems like a really fun option, but I did see some welding on page 2 or 3 that has put me off a bit. I can work on a lot myself, but wouldn't be able to pull that off.

Here's one near me that looks great --> http://denver.craigslist.org/ctd/3610224143.html

So, is there a specific build, year, mileage, that would be best here? Ultimately I'm looking for the ability to do the 31 inch tires and eventually a full time 4x4 option.

Thanks!

Hi driver3. For me, I would stay with exactly what I have, 2003-2005 Astro/Safari awd, GT4 (3.73 gear ratios), G80 (locking rear differential), tow package, rear heat & a/c (noticeable improvement in heating/cooling). The larger front discs/calipers and rear disc setup are a big improvement in braking efficiency, pad and rotor wear is minimal and less maintenance. I'm still on original rotors and went through one set of Hawk LTS on the front and swapped back to the original pads which I'm still using. I believe it was '99 when they went to the electronically controlled transfer case which seems to make two-speed transfer case swap a relative breeze. Six-bolt hubs and 16" wheels are nice too but certainly not a requirement.

The welding is not necessary as you could just install longer shocks as opposed to relocating the lower shock mounts on the rear axle. The benefits of welding new lower shock mounts is that you can possibly reuse stock shocks (depending on how much lift you've done) and they are no longer below the rear axle to snag or hangup on anything. There is a way to cut, bend and drill the lower shock mounts to relocate a bit higher which I've seen done on A/S forums.

Of course I waited until now to look at the van classified link you posted and it looks like a nice clean van, if priced a bit high for its age. It does have GT4, G80, rear heat and a/c which is nice. I really put some miles on my '97 Safari AWD in the snow and it was pretty outstanding with snow tires and felt like maybe the full time awd with viscous t-case was a better setup for that kind of environment, powering both axles all the time as opposed to kicking in when sensing speed difference like the electronic t-case but sounds like you want to go 2-speed t-case anyway.

With 4" lift, 31" tires will still require some cutting, grinding and hammering.

 

[mapper]

So, if you were to do it again, is there a different van you would like to start with? I'd love to do this, but I'm far from pulling the trigger. I live in CO and drive 20k+ miles a year. We are in the mountains every weekend and an awd van would be awesome for what I do. My last two cars have been an H3 with the adventure package and now a bmw xi wagon. SUV was good, but no room, and the bmw actually has more room and more mpg, but not off road at all (obviously). This seems like a really fun option, but I did see some welding on page 2 or 3 that has put me off a bit. I can work on a lot myself, but wouldn't be able to pull that off.

Here's one near me that looks great --> http://denver.craigslist.org/ctd/3610224143.html

So, is there a specific build, year, mileage, that would be best here? Ultimately I'm looking for the ability to do the 31 inch tires and eventually a full time 4x4 option.

Thanks!

These vans are a great option. I love tossing bikes, gear, dogs, whatever in the van for my trips. When I elect to take the van out I don't even need to think about packing light...if I want it, I bring it and have room to spare. Quick and easy for those compressed, long weekend excursions. My van has about a 2-3" lift, no body pucks just Tbar crank, rear shackles, helper springs and I run 235 70 16 AT tires. The lowest point on my van is the diff (8.5") and original rear shock mounts (9"). I also have a Volvo XC70 which is probably somewhat comparable, maybe slightly higher, it's low point is 7.75", to your x1. I'd say my van easily splits the difference btw the capabilities of the x1 and the H3. These vans are quite capable, anyone who rides with me is shocked where I take it and I know I haven't even begun to test the limits. I'd also like to someday consider the 2 speed TC swap but for anything but truly technical trails the van works pretty good as it sits. I say go for it...took a bit for the van to grow on me but I love it and the Astro/Safari community.

One more thing. For being a dated design and boxy design, the newer models actually cruise down the highway quite nicely. Especially on good AT tires.

 

[Stroverlander]

I've been driving these vans for well over a decade now with only a few other vehicles in the mix during that time (motorcycles excepted!), but not many so nice to see mapper's input or anyone else that drives other vehicles more frequently.

As for the lift, it's simple and straightforward, choose your desired outcome and go for it! Mapper is correct, they do get down the highway (and other places!) pretty well decently suspended and a bit larger A/T tires.

 

[Stroverlander]

Recently, while perusing and organizing photo albums of Stroverlander, I came across a few things I thought were relevant to the build thread that didn't make it in so went back through the thread and added some items I left out. Didn't think they were worthy of new, additional posts on their own but may help others so added them to existing posts around the same time the work was performed. I also snuck in a few more photos in places just because I can, though you'd probably have to be an ardent observer of this thread to notice. Then I realized that the list of ardent observer(s) may only include myself, so I've included links to the updates... :sombrero:


Stroverlander Intermittent ABS Fault Resolved - Repaired ABS Module

Quick Blurb On Rear Drivetrain Vibes

Stroverlander, Summer Cool & Quiet, A/C Clutch Kit Install

 

[Stroverlander]

Sway Bar Bushings & End Links, Body Mount Bushings & Maintenance

Some new replacement parts to try and tighten up a few areas of the van and adjust the sway bar a bit more parallel after torsion lift. The Moog Problem Solver swaybar bushings and end links had definitely seen better days.

The bushings were no longer holding the sway bar tight and swaybar would shift slightly and rub tire at near full lock. Also, the end link bushings had flattened out unevenly due to the downward angle of swaybar and control arm from the torsion lift so want to alleviate that somewhat. I considered shimming the sway bar subframe bushing to move down but space is limited with idler arm right under bushing shell so went with slightly longer end links.

I compared and researched stock parts with aftermarket and came up with Energy Suspension Hyper-Flex urethane sway bar bushings to fit my 30mm (1 3/16") swaybar and an Adjust-A-Link end link kit. I'm also going to be making a few more improvements/modifications to Stroverlander in the near future so wanted to procure a few other bits and pieces. No one really lists any urethane performance products for the Astro/Safari so went to work cross referencing part numbers for body/subframe bushings (with a lead from an A/S forum member for an older Chevy pickup that used the same bushings for cab mounts) and came up with this Prothane urethane body/subframe bushing kit.

While the swaybar bushings are greasable, I'll most likely need to relocate the zerk fittings due to interference with idler arms so will plug those holes with set screws and then drill new holes offset from center for zerk fittings.

I'll get the swaybar parts installed in the next few days and then body/subframe bushings when I have the remaining pieces together for subframe.

I finally fixed the chronic faulty hood release mechanism, guess I was just finally tired of pulling on the release handle only to not have the hood pop open and so resort to tapping on the hood. Then when the hood would finally release, continue fighting with the wobbly and flimsy release catch on the hood. Having tried adjusting the latch mechanism in the past with no results, I finally thought about it for a minute and narrowed it down to the flimsy/wobbly hood catch release mechanism. Too much play in the separate pieces where they are held together by the peened over hinge pin. I marked the location of the mechanism and removed from the hood to see if I could reduce the play in the hinge pin. I tried a couple of attempts with a drift but that wasn't happening and didn't have a vise at my disposal so moved on to my heavy duty motorcycle chain breaking tool.

The hinge pin happened to fit in the chain tool well enough and so started cranking down and backing off to check my work. Looked like it was working as anticipated so kept going and then did a second spot for good measure. End result, a much tighter assembly with very little play!

Installed back on the van, aligned properly and then tested. Pulled on the hood release inside footwell and the hood popped open on the first attempt, like it was meant to. The misalignment of the catch when closed was keeping the hood from releasing almost every time. Next test, reaching under the hood and pulling up on the release to lift hood also works like it supposed to - moving straight up and releasing from the catch without any drama at all. Almost too well for the years I've been just been living with this issue. :Wow1:

It's a one hander now and no more embarrassing love taps on the hood. Twenty minutes of work to end years of frustration, all those little annoyances can add up! :yikes:

Works so smooth, I had to provide proof! Video link:


I noticed a few HVAC vacuum lines had seen better days and vent position changes were slowing down so replaced the deteriorated HVAC rubber vacuum lines that attach the vacuum tank (ball) to the heater & AC control valve with some urethane hose I had on hand. Sure seems like urethane is the going trend in this post for some reason!

Disconnected the old rubber line coming from vacuum tank to test fit the urethane hose, can see just how deteriorated the rubber line is.

The other rubber and vacuum lines seemed to be in good condition. I previously replaced the common broken vacuum line with the two 90°elbows that runs across the top of the engine.

New hose installed on the vacuum tank.

I noticed while installing above that I have weeping transmission cooler lines so I'll be repairing those instead of replacing, adding an inline filter once I determine the correct size and sorting out some quality high pressure transmission cooler hose and suitable clamps.