1991 Chevrolet Astro

Introduction

The 1991 Chevrolet Astro is a compact van that was offered with two engine and two transmission options. The 4.3L V6 engine produced 160 horsepower and 225 lb-ft of torque, while the 5.7L V8 engine produced 210 horsepower and 300 lb-ft of torque. Both engines were available with either a four-speed automatic transmission or a five-speed manual transmission. The Astro was praised for its spacious interior and comfortable ride, but it was criticized for its poor fuel economy and lack of power.

Engine

4.3L V6

• Intake manifold gasket failure: The intake manifold gasket can fail, causing coolant and oil to leak. Symptoms include engine overheating, low coolant levels, and rough idle. The solution is to replace the intake manifold gasket. Estimated cost to fix: $200 - $600
• Valve cover gasket failure: The valve cover gasket can fail, causing oil to leak. Symptoms include oil leaks on the engine block and a burning smell in the cab. The solution is to replace the valve cover gasket. Estimated cost to fix: $100 - $300
• Head gasket failure: The head gasket can fail, causing coolant and oil to mix. Symptoms include white smoke from the exhaust, overheating, and low coolant levels. The solution is to replace the head gasket. Estimated cost to fix: $1,000 - $2,500

5.7L V8

• Intake manifold gasket failure: The intake manifold gasket can fail, causing coolant and oil to leak. Symptoms include engine overheating, low coolant levels, and rough idle. The solution is to replace the intake manifold gasket. Estimated cost to fix: $200 - $600
• Valve cover gasket failure: The valve cover gasket can fail, causing oil to leak. Symptoms include oil leaks on the engine block and a burning smell in the cab. The solution is to replace the valve cover gasket. Estimated cost to fix: $100 - $300
• Head gasket failure: The head gasket can fail, causing coolant and oil to mix. Symptoms include white smoke from the exhaust, overheating, and low coolant levels. The solution is to replace the head gasket. Estimated cost to fix: $1,000 - $2,500

Transmission

Four-speed automatic

• Transmission slipping: The transmission may slip out of gear or hesitate to shift. Symptoms include loss of power, delayed gear engagement, and a burning smell. The solution is to rebuild or replace the transmission. Estimated cost to fix: $1,500 - $3,000
• Torque converter failure: The torque converter may fail, causing the transmission to slip or shudder. Symptoms include loss of power, delayed gear engagement, and a burning smell. The solution is to replace the torque converter. Estimated cost to fix: $500 - $1,200

Five-speed manual

• Clutch failure: The clutch may fail, causing the transmission to slip or not engage. Symptoms include difficulty shifting gears, slipping gears, and a burning smell. The solution is to replace the clutch. Estimated cost to fix: $500 - $1,000

Suspension

• Ball joint failure: The ball joints may fail, causing the front end to shake or wobble. Symptoms include clunking noises, wandering steering, and uneven tire wear. The solution is to replace the ball joints. Estimated cost to fix: $200 - $400
• Tie rod failure: The tie rods may fail, causing the steering to feel loose or unresponsive. Symptoms include wandering steering, uneven tire wear, and a knocking noise when turning. The solution is to replace the tie rods. Estimated cost to fix: $200 - $400
• Sway bar link failure: The sway bar links may fail, causing the vehicle to roll excessively or feel unstable around corners. Symptoms include clunking noises, wandering steering, and excessive body roll. The solution is to replace the sway bar links. Estimated cost to fix: $100 - $200

Electrical

• Alternator failure: The alternator may fail, causing the battery to not charge. Symptoms include dim headlights, electrical system problems, and a dead battery. The solution is to replace the alternator. Estimated cost to fix: $300 - $700
• Starter failure: The starter may fail, causing the engine to not start. Symptoms include clicking noises when trying to start the engine, a dead battery, and no power to the dashboard. The solution is to replace the starter. Estimated cost to fix: $200 - $500
• Battery failure: The battery may fail, causing the vehicle to not start. Symptoms include dim headlights, electrical system problems, and a dead battery. The solution is to replace the battery. Estimated cost to fix: $100 - $250

Exterior

• Rust: The Astro is prone to rust, especially on the body panels, frame, and undercarriage. Symptoms include visible rust spots, holes in the body panels, and a weakened frame. The solution is to treat the rust and prevent it from spreading. Estimated cost to fix: $500 - $5,000+

Interior

• Dashboard cracking: The dashboard may crack over time. Symptoms include cracks and peeling on the dashboard surface. The solution is to replace the dashboard or repair the cracks. Estimated cost to fix: $500 - $1,500
• Seat foam degradation: The seat foam may degrade over time, causing the seats to become uncomfortable or sag. Symptoms include flat or sunken seats, back pain, and discomfort. The solution is to replace the seat foam. Estimated cost to fix: $300 - $700
• Carpet staining: The carpet may stain over time, especially if it is not cleaned regularly. Symptoms include visible stains, discoloration, and a musty odor. The solution is to clean the carpet or replace it if it is too damaged. Estimated cost to fix: $100 - $500

Summary

The 1991 Chevrolet Astro is a reliable and affordable van, but it is not without its issues. The most common problems include intake manifold gasket failure, valve cover gasket failure, head gasket failure, transmission slipping, and torque converter failure. These issues can be expensive to fix, but they are not uncommon for vehicles of this age and mileage. Overall, the Astro is a good choice for those who need a spacious and comfortable van, but it is important to be aware of its potential problems before buying one.