1991 Chevrolet Astro: Recalls, Problems & MPG
Here are the deets on the 1991 Chevrolet Astro: 3 recalls, 95 owner complaints and up to 17 mpg combined.
Recalls
3 vehicle recalls from the manufacturer, plus 3 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Seat belts Vehicle recall #91V102000 · 1991 · 185 vehicles
What's wrong: The seat belts for the front and mid-ship seats did not rest on pelvis as required by fmvss 209.
Why it matters: Seat belts May not restrain seat occupant, and couldinjure the seat occupant in the event of a sudden stop or accident.
The fix: Relocate seat belt anchor bolts to adjust belts for seat locations.
Seat belts Vehicle recall #91V164000 · 1991 · 4,842 vehicles
What's wrong: Seat belt anchorage bar for rear sofa failed to sustain loads required by fmvss 210.
Why it matters: Vehicles would not comply with fmvss 210.
The fix: Replace noncomplying sofa bar with bar that meets requirements.
Seats Vehicle recall #93V187000 · 1993 · 604,207 vehicles
What's wrong: The recliner mechanism and the seat frame May have foam and/or vinyl between them, creating a "soft" joint. This "soft" joint results in lower than specified bolt torque which leads to joint looseness, causing bolt fatigue and eventual bolt failure.
Why it matters: If bolt failure occurs to the driver's seat, it wouldallow the seat back to suddenly recline, and could result in loss of vehiclecontrol and a vehicle crash without prior warning.
The fix: Dealers will remove the foam and/or vinyl from between the recliner mechanism and the seat frame "soft" joint and replace the recliner bolts.
3 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Exterior lights Equipment recall #06E026000 · 2006 · 61,944 vehicles
What's wrong: Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. Some combination lamps that are not equipped with amber side reflectors fail to conform to Federal Motor Vehicle Safety Standard no. 108, lamps, reflective devices, and associated equipment.
Why it matters: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
The fix: Pro-a motors will notify owners and offer to repurchase the lamps. The recall began on April 3, 2006.
Fuel system Equipment recall #06E043000 · 2006 · 88,303 vehicles
What's wrong: Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from October 18, 2005, through March 21, 2006, sold for use on the vehicles listed above and on certain school buses. (to see the school bus engine sizes, click on "document search" and then "bus applications"). The…
Why it matters: This condition May cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
The fix: Honeywell will notify owners and replace the fuel filters free of charge. The recall began on October 18, 2006.
Exterior lights Equipment recall #06E049000 · 2006 · 27,176 vehicles
What's wrong: Certain ck motorsports combination headlights, clear corner, bumper, and side marker lights sold as replacement lamps for use on the passenger vehicles listed above. Some combination lamps that are not equipped with amber side reflectors fail to conform to Federal Motor Vehicle Safety Standard no. 108, lamps, reflective devices, and associated equipment.
Why it matters: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
The fix: Ck motorsport will notify owners and replace the noncompliant lamps free of charge. The recall began on July 1, 2006.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 4 mention a fire, 10 injuries and 0 deaths were reported.
What owners describe
- Brakes (hydraulic) (42): the most common themes are brake failure / soft pedal (18), warning light on (9).
- Body & structure (10): the most common themes are door / lock issues (9).
- Electrical (8): the most common themes are electrical failure (6), fire / smoke (3).
- Seat belts (7): no single recurring theme in the descriptions.
The 1991 Chevrolet Astro has 95 owner complaints, ranking #10 of 16 Astro model years for complaints (well below the 164 average). Complaints peaked in 1995 (23 filed that year). The typical problem showed up when the car was about 5 years old, at a median of 258,900 miles. Neighboring years: 1990 (68 complaints, 4 recalls), 1992 (132 complaints, 1 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 4.3 L 6-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 15 | 20 | 17 | Regular |
| 4.3 L 6-cyl | Automatic 4-spd | Rear-Wheel Drive | 15 | 20 | 17 | Regular |
| 4.3 L 6-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 14 | 18 | 16 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 1991 Chevrolet Astro.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
From $19.99/mo · $39.99/yrOEM procedures, specs and recall/TSB info, the same source many shops use.
From $19.99/mo · $59.99/yrStep-by-step photos written from a real teardown. Great for first-timers.
Books ~$30–$40 · AllAccess $34.99/moHeads up: we may earn a commission if you buy through these links, at no extra cost to you. Prices checked 2026-10 and can change. We never host or link to pirated manuals. Disclosure
FAQ
Does the 1991 Chevrolet Astro have any recalls?
Yes. NHTSA lists 3 vehicle recalls for the 1991 Chevrolet Astro, plus 3 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 1991 Chevrolet Astro problems?
Owners have filed 95 complaints with NHTSA. The most-reported areas are brakes (hydraulic) (42), body & structure (10), electrical (8).
What gas mileage does the 1991 Chevrolet Astro get?
EPA ratings run up to 17 mpg combined (4.3 L, Automatic 4-spd), across 3 engine and transmission combos.
Where can I get a 1991 Chevrolet Astro repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.