Faults:

The fuel injection system had to be replaced at 50,000 miles.

The fuel pump failed and had to be replaced at 70,000 miles.

The windshield wiper motor has had to be resoldered twice because it has failed.

The rear air relay under the dash had to be replaced at 100,000 miles due to the power wire shorting and melting the housing.

The oil gauge flicks back and forth during driving. The oil sending unit has been replaced and the pump has been tested and in working order.

Front end needs to be replaced now. Idler arms are very worn and a 'crunch' noise occurs during slow turns.

Tires wear pretty quickly on the front.

General Comments:

The van has been good, dependable transportation for a family with 4 kids growing up.

Although the list of problems seems long it is complete and we have owned the van for 5 years and put 140,000 miles on it.

Rear air is a requirement for owners living in the south.

Faults:

Rear differential rebuilt at about 33,000 miles, under warranty.

Air conditioning leaky, at 38,000 miles dealer couldn't find problem, still charged $150. My non-dealer mechanic found and fixed problem, leaky condenser.

Intake manifold gasket failed at 65,000 miles. Expensive repair.

Front right transaxle seal failed at 70,000.

Windshield wiper control circuit card failed at 70,000.

Idler arms worn out and replaced at 77,000 miles and again at 102,000. Mechanic says it is normal with the Astro Van.

EGR valve recall and cleaned by (I don't know why they didn't replace it...) dealer at 70,000 miles. Took care of intermittent rough running and check engine light.

I replaced my own spark plugs at about 70,000 miles. Right side not bad, but left was nearly impossible. Really poor access clearance from underneath or from on top.

Front brake rotors are composite material and few people will re-surface them. Replacement cost is $150 each.

General Comments:

I have been very disappointed in this vehicles poor reliability and design.

The road handling is very weak, when a highway sign suggests a speed for a curve, better slow down to that and then slow down another 5 to 10 MPH.

To own this vehicle you must have a great relationship with your mechanic!