jpowerdiver
New member
Does anybody have experience with Chevy Astro van AWD reliability? Specifically the AWD components. I’m thinking of buying a 2000-2005 model year for a camper conversion.
Reliability of Chevy Astro van AWD
- Thread starter jpowerdiver
- Start date
vintageracer
To Infinity and Beyond!
The "Plastic Spider" in the 4.3 Vortec fuel injection system under the plenum can be problematic with higher mileage Astro/Safari's. There is an upgraded Spider available that fixes the problem. The front wheel bearings and axle shafts (CV) joints need periodic service/rebuilt. The transfer case is viscous and therefore the driveline is AWD not 4WD. There is a difference. You can change out the AWD transfer case to a manual shift HI/LO range 4WD transfer case if desired. Front differential has a small ring gear therefore not very heavy duty however just fine for what it was designed for. Rear leaf springs are fiberglass which many folks upgrade to steel for better load capability. Installing a 2-4 inch lift can be done. The front suspension is equipped with torsion bars which limits the height and type of lift you can install and still maintain decent front suspension geometry. Tire size is limited by the van body and front suspension design.
Overall the AWD Astro is good driving and comfortable mid-size van that does well if used for the designed purpose. GREAT in the snow and fair at best off-road with limited capability.
Most ALL of your questions can be answered over at:
https://www.astrosafari.com/index.php?sid=59edf264a91d05922d28fdfad3d95d15
Overall the AWD Astro is good driving and comfortable mid-size van that does well if used for the designed purpose. GREAT in the snow and fair at best off-road with limited capability.
Most ALL of your questions can be answered over at:
https://www.astrosafari.com/index.php?sid=59edf264a91d05922d28fdfad3d95d15
Trikebubble
Adventurer
I just retired my 2000 Astro Van (2wd) with close to 300K km on it. It finally needed some cylinder head work and just wasn't cost effective to repair anymore and I needed a newer van for work anyways. (I've given it to some friends who own a farm and it will continue to serve them for years to come I'll bet)
However, it was a fantastic van. I wish they still made them, I'd be driving another new one today. The only real maintenance issues I kept on top of was replacing the fuel filter very regularly. Like with every oil change. Simple and easy to do. The fuel pump will otherwise let you know if you don't change it regularly. The rubber vacuum hoses that (I think I've got this right) that connect to the heater and A/C controls wear out and cause the heater and A/C to just not work right. I believe people replace them lines with better silicone tubing or something like that.
However, it was a fantastic van. I wish they still made them, I'd be driving another new one today. The only real maintenance issues I kept on top of was replacing the fuel filter very regularly. Like with every oil change. Simple and easy to do. The fuel pump will otherwise let you know if you don't change it regularly. The rubber vacuum hoses that (I think I've got this right) that connect to the heater and A/C controls wear out and cause the heater and A/C to just not work right. I believe people replace them lines with better silicone tubing or something like that.
I have a 2003 AWD. And therein is really the answer to your question: it's 15 years old.
Things are going to go wrong, for sure. I bought mine from a friend who is meticulous with maintenance, and still I've had to repair/replace a rear throw out bearing, the fan clutch, the thermostat, the ABS module (twice), the hydroboost unit, and the aforementioned fuel injection spider (also twice because the first replacement part was defective - total PITA).
Next on my list are the A/C blower fan and its resistor pack and a vacuum canister (which btw is unavailable retail; I have to pull one off a pick n pull donor).
So you might wonder if I'd do it again or get another Astro. Definitely. They're inexpensive and have a ton of potential. They fit in any parking space (smaller than a Lexus ES350) and the visibility is better than any car I've ever driven.
I've lifted mine 4" and added nice wheels and tires. It takes me everywhere I want to go and gets tons of attention along the way. Just this weekend, in fact, two guys in a 911 GT3 ($147K in case you're wondering; I Googled to check!) gave me huge thumbs up and the passenger yelled out the window, "I LOVE that!!."
I picked up a used Westfalia propane tank yesterday for $20. And my neighbor gave me three used 10-gallon stainless steel pool filter canisters that I'm going to re-purpose into water tanks that will mount where the spare tire is now by moving the spare up to a custom rear door swingout.
A roof rack, solar, a 12v fridge and interior buildout are in process too. At some point I'll do a V-8 swap with hi-lo 4x4 transfer case.
Quite a transformation for something that started life as a kid hauler. And even when all is said and done, I'll be in it for less than $25K. For me, that's the fun of it. I can do something totally capable and totally custom without having to donate an organ.
Things are going to go wrong, for sure. I bought mine from a friend who is meticulous with maintenance, and still I've had to repair/replace a rear throw out bearing, the fan clutch, the thermostat, the ABS module (twice), the hydroboost unit, and the aforementioned fuel injection spider (also twice because the first replacement part was defective - total PITA).
Next on my list are the A/C blower fan and its resistor pack and a vacuum canister (which btw is unavailable retail; I have to pull one off a pick n pull donor).
So you might wonder if I'd do it again or get another Astro. Definitely. They're inexpensive and have a ton of potential. They fit in any parking space (smaller than a Lexus ES350) and the visibility is better than any car I've ever driven.
I've lifted mine 4" and added nice wheels and tires. It takes me everywhere I want to go and gets tons of attention along the way. Just this weekend, in fact, two guys in a 911 GT3 ($147K in case you're wondering; I Googled to check!) gave me huge thumbs up and the passenger yelled out the window, "I LOVE that!!."
I picked up a used Westfalia propane tank yesterday for $20. And my neighbor gave me three used 10-gallon stainless steel pool filter canisters that I'm going to re-purpose into water tanks that will mount where the spare tire is now by moving the spare up to a custom rear door swingout.
A roof rack, solar, a 12v fridge and interior buildout are in process too. At some point I'll do a V-8 swap with hi-lo 4x4 transfer case.
Quite a transformation for something that started life as a kid hauler. And even when all is said and done, I'll be in it for less than $25K. For me, that's the fun of it. I can do something totally capable and totally custom without having to donate an organ.
Binky
Member
I have a 2000 AWD Astro with a 3" lift. We love it. While lots of little things will need attention, they are super cheap and easy to work on. At 260,000 miles, the trans finally gave out. My wife likes it so much that she'd rather replace the trans ($2k) than think abut a different car. I built mine so I could pull the table and bed in about 5 minutes for hauling wood, drywall, motorcycles, etc. Was planning the NP233 transfer case before I bought binky.
Mwilliamshs
Explorer
A throw out bearing interfaces between a clutch fork and pressure plate in a manual transmission. There's only one, so not sure why there would be a front and rear designation.
You have a manual transmission in an Astro? Never seen that. Got pics?
Billy_Bottle_Caps
New member
I had a gold 5-speed Astro couple years ago. Will check my old computer and see if I still have pics of it.
Maybe I have it wrong. A shop did the work and that's what I remember them saying. It was a bearing in the rear end that was scored pretty badly.
arlon
Adventurer
I have a 2004 AWD Astro and really like the thing. It has close to 90k miles on it now. Got it with very low miles, has 3.73 gears and and a factory rear locker. I did a 2" lift and some larger tires. My only real issue with the Astro is it's lack of power with the larger tires. It struggled with 225/75/16 AT/KO (E-rated). Those tires killed the vans performance.I still wore those tires out and just replaced them 225/70 Cooper AT3 MS4 tires. That size makes the van feel so much better.
I have had almost no maintenance issues. I did have to replace the rear ABS sensors to get the brake light to go off. Easy fix. I do replace the fuel/air filters more frequently than in other cars. I'd happily drive the van anywhere. I love the smaller footprint of the Astro. I like it's stealth, I can nap about anywhere and nobody knows I'm in there. I like that I don't have to tow anything. I do not do crazy off road stuff so the AWD is fine. I can't recall anywhere I have even spun a tire since I got this van. It may not be a Rubicon but it will still go into a lot of places and I can sleep in it when I get there.
One thing that worries me a bit about the Astro is the boulder buster cast aluminum oil pan that hangs below everything. It hangs a good inch below everything else under the van. I wish someone made a decent skid plate for it! I'd sure feel better if it had something to protect that oil pan.
I have had almost no maintenance issues. I did have to replace the rear ABS sensors to get the brake light to go off. Easy fix. I do replace the fuel/air filters more frequently than in other cars. I'd happily drive the van anywhere. I love the smaller footprint of the Astro. I like it's stealth, I can nap about anywhere and nobody knows I'm in there. I like that I don't have to tow anything. I do not do crazy off road stuff so the AWD is fine. I can't recall anywhere I have even spun a tire since I got this van. It may not be a Rubicon but it will still go into a lot of places and I can sleep in it when I get there.
One thing that worries me a bit about the Astro is the boulder buster cast aluminum oil pan that hangs below everything. It hangs a good inch below everything else under the van. I wish someone made a decent skid plate for it! I'd sure feel better if it had something to protect that oil pan.
Binky
Member
Arlon,
I bought a 2'x6' piece of 1/4" aluminum for a skit plate. Covers the oil pan, trans and x-fer case. Cost about $150 in materials and to have the shop that cut it to size, add three bends in their press. Then a few holes and some brackets and everything from behind the radiator to the trans cross member is covered.
I suffered form a lack of power for a long time, I finally tracked it down to the AMM. $45 Amazon unit later and it runs perfect. I run 235/75-15 Firestone Destination A/T's w/ the same rear end you have.
If you want an Astro, I think the 2003-2006 (the '16'er) is the way to go. I'm sure that's what Herbie and T.Lowe (?) have.
John
I bought a 2'x6' piece of 1/4" aluminum for a skit plate. Covers the oil pan, trans and x-fer case. Cost about $150 in materials and to have the shop that cut it to size, add three bends in their press. Then a few holes and some brackets and everything from behind the radiator to the trans cross member is covered.
I suffered form a lack of power for a long time, I finally tracked it down to the AMM. $45 Amazon unit later and it runs perfect. I run 235/75-15 Firestone Destination A/T's w/ the same rear end you have.
If you want an Astro, I think the 2003-2006 (the '16'er) is the way to go. I'm sure that's what Herbie and T.Lowe (?) have.
John
Deshet
Adventurer
The 4.3 engine and the tranmission are extremely reliable.
The engine is a Chevy 350 with 2 cylinder missing. The 350 Chevy had about a 50 year production run, it was found in trucks, vans, cars corvettes, boats, buses, etc. I am sure that the engine is still made. Everyone knows something about the Chevy 350 V8 and it should be able to be fix anywhere in the World. Every part is available online. Every combination of powered adders is well know. You can actually go to a junk yard and find good stuff.
It may be the most massed produced engine every made. The 4.3 is a 350 (5.7) chevy without two cylinders
Even if you hate Chevy you have a little respect for the 350
The engine is a Chevy 350 with 2 cylinder missing. The 350 Chevy had about a 50 year production run, it was found in trucks, vans, cars corvettes, boats, buses, etc. I am sure that the engine is still made. Everyone knows something about the Chevy 350 V8 and it should be able to be fix anywhere in the World. Every part is available online. Every combination of powered adders is well know. You can actually go to a junk yard and find good stuff.
It may be the most massed produced engine every made. The 4.3 is a 350 (5.7) chevy without two cylinders
Even if you hate Chevy you have a little respect for the 350
Last edited:
MOguy
Explorer
The 4.3 seems to be reliable. My kid has a 97 s-10 with just over 200k and the 4.3 it runs fine. His is a 5 speed, when we bought this one it seemed many from this time area that had auto trans had trans issues, no sure if the would be an issue with the newer ones.
As far as the spider? We just replaced one a few times in a 5.7 suburban. After you do it a couple times it gets easy. After replacing we discovered there was a head issue and he had gotten a bad spider. It seems the spiders may go out at about 200k and it isn't to uncommon to get a bad replacement one.
As far as the spider? We just replaced one a few times in a 5.7 suburban. After you do it a couple times it gets easy. After replacing we discovered there was a head issue and he had gotten a bad spider. It seems the spiders may go out at about 200k and it isn't to uncommon to get a bad replacement one.
Herbie
Rendezvous Conspirator
Correct. The 6-lug vans (2003-2005) have a significant brake upgrade both front and rear (including the rear going to discs). Big help for the vans as they get heavier if you load them down. (Like mine!)
Stroverlander
Adventurer
Yeah, if going to buy and build one, best to go with 2003-2005 with larger discs all around. The fuel spider and injectors are already updated on later years. Any vehicle of the age range you are looking at is going to have maintenance requirements. Don't be silly abusive with the AWD drivetrain and it's reliable, enough.