Chevrolet Astro

Chevrolet Astro
Manufacturer	General Motors
Also called	GMC Safari
Production	1985–2005
Class	Minivan
Body style(s)	3-door van
Layout	Front engine, rear-wheel drive / Four-wheel drive
Platform	M-body
Transmission(s)	4-speed automatic

First generation

Production	1985–1994
Assembly	Baltimore, Maryland
Engine(s)	4.3L 165 hp (123 kW) V6 4.3L 200 hp (150 kW) V6 2.5L I4
Wheelbase	111.0 in (2819 mm)
Length	SWB: 176.8 in (4491 mm) LWB: 186.8 in (4745 mm) 1992-94 Astro Cargo Van SWB: 177.9 in (4519 mm) 1992-94 Astro Cargo Van LWB: 187.9 in (4773 mm)
Width	77.0 in (1956 mm) 1992-94 Safari & Astro Cargo Van: 77.5 in (1969 mm)
Height	1985-89: 73.7 in (1872 mm) 1985-89 Cargo Van SWB: 74.5 in (1892 mm) 1990-91 SWB: 74.9 in (1902 mm) 1990-91 SWB: 74.1 in (1882 mm) 1992-94 Astro: 76.2 in (1935 mm) 1992-94 Safari Cargo Van: 76.1 in (1933 mm) 1992-94 Safari SLX: 76.4 in (1941 mm) 1992-94 Safari 2WD LWB: 76.6 in (1946 mm) 1992-94 Safari Cargo Van AWD SWB: 75.7 in (1923 mm) 1992-94 Safari Cargo Van AWD LWB: 76.0 in (1930 mm)

Second generation

Production	1995–2005
Assembly	Baltimore, Maryland
Engine(s)	4.3 L 190 hp (140 kW) V6
Wheelbase	1995-96: 111.0 in (2819 mm) 1997-2005: 111.2 in (2824 mm)
Length	189.8 in (4821 mm)
Width	77.5 in (1969 mm)
Height	1995-96 Astro: 75.9 in (1928 mm) 1997-98 Astro: 76.0 in (1930 mm) 1995-96 Safari: 76.2 in (1935 mm) 1997-98/2002-03 Safari Cargo Van & 1999-2001 Astro Cargo Van 2WD: 75.3 in (1913 mm) 1997-2005 Safari & 2002-05 Astro: 75.0 in (1905 mm) 1999-2001 Astro 2WD: 74.9 in (1902 mm) 1999-2001 Astro Cargo Van AWD: 75.2 in (1910 mm) 1999-2001 Astro AWD: 74.8 in (1900 mm)

1st-gen GMC Safari

1997 GMC Safari

The Chevrolet Astro was a rear-wheel drive minivan introduced by Chevrolet in 1985 to rival domestic (American) competitors the Dodge Caravan/Plymouth Voyager twins and the Japanese Toyota Van. Also sharing the Astro's truck-based platform was its sibling, the GMC Safari. In addition to standard passenger uses, the vans were also available as cargo vans, and converters used them as the basis for small conversion vans.

Both Pontiac and GMC have used the Safari nameplate (GMC is part of the Pontiac/GMC division); Pontiac used the nameplate on several of its station wagon models from 1955 through 1989. The two Safaris, both Pontiac and GMC, were on the market together (often sold by the same dealerships) from 1985 through 1989.

While the Astro was referred to as a minivan, it was sized between the Chevrolet Venture/Lumina APV unibody minivan and the full-size Chevy Van/Express. Similar to the Ford Aerostar, it was based on a traditional truck frame.

Due to their truck-based platform, the Astro and Safari could pull 5,500 lb (2,500 kg) with proper equipment. AWD models could tow up to 5,000 lb (2,300 kg) when properly equipped. This is opposed to car-based, front-wheel drive minivans (most of which are limited to a 3,500 pound towing capacity)that cannot pull as much weight.

Initial advertising boasted that it was a vehicle that will "make you realize that life is too big for a minivan", referring to the Chrysler minivans.

Engines options ranged from 145 to 190 hp (108 to 142 kW) V6 engine, depending on options and/or model year.

The van seated up to 8 passengers.

In addition to being sold in North America, the Chevrolet Astro was exported to Japan, where the van enjoys a cult following. In 2005, to celebrate the last year of Astro production, Chevrolet of Japan offered a limited edition run of the final production models. The Astro's popularity in Japan comes even though it was only offered in left-hand drive.

Chassis features

Much like the second-generation GM F-body and X-body vehicles, the GM M-van (Astro/Safari) had a bolt-on subframe incorporating the front suspension from a GM B-body station wagon (Chevrolet Caprice, Cadillac Brougham) with a leaf-spring rear suspension. The lower ball joints were larger than their B-body counterparts (similar to 1977-96 Cadillac D platform vehicles e.g. Fleetwood limousines). These ball joints were later used in the final Chevrolet Caprice 9C1 (police package) cars manufactured in 1995 and 1996. They also shared many mechanical similarities to the GMT 325/330 midsize S/T Pickup/Utilities.

As mentioned above, the Astro and Safari were rear-wheel drive vehicles, but in 1990 a new all-wheel drive (AWD) system, designed and developed by FF Developments (FFD), was made optional. The AWD models had a lower fuel economy: 17 miles per gallon highway versus 20-21 for rear-drive vans. Premature idler arm wear on the AWD front suspension is a common problem.

Hundreds of instances of front torsion bar failure in the AWD suspension were reported to NSHTA. The torsion bars failed without warning, resulting in bottoming of the suspension. Repair required replacement of both torsion bar assemblies with upgraded designs at a cost of about $1000. No fatalities were reported.

In 1990, a new dash was introduced along with the availability of a long-wheelbase model. In 1995, the model was face lifted with an extended nose that resembled the then-new full-size Express vans. In 1996, a redesigned dash received a passenger side air-bag. The vans remained mostly unchanged until canceled in 2005.

In 2003, GM upgraded the chassis of both the Astro and Safari with certain suspension components, larger brakes, and six-lug, 16 inch wheels from the full-size Chevrolet and GMC half-ton pickup trucks. The modifications improved the poor handling and braking of the vans.

End of the line

Faced with falling sales across its vehicle lines, General Motors began closing plants and discontinuing slow-selling vehicle lines. With new federal standards for side impact and head injury reductions coming, GM determined that there was no use in expending money for a redesign of a vehicle line that was no longer selling well. Thus, the Safari and Astro were taken out of production in May 14, 2005, and the long-serving Baltimore, Maryland assembly plant where both were built was closed. It was the only rear-wheel drive minivan which was produced for 20 model years - a longer run than its nearest rival, the Ford Aerostar, which ceased production in 1997, and the only remaining rear-wheel drive minivan in the United States and Canada since the original Mazda MPV ceased production in 1998. It was also the only rear-wheel drive minivan in the United States and Canada to spawn two generations. In total, the Baltimore plant produced approximately 3,700,000 Astro and Safari vans.

In the Chevrolet line, the Astro was replaced by the Chevrolet Uplander "crossover sport van", which also replaced the Chevrolet Venture. Like the Astro, the Uplander is available in cargo and passenger versions, although its front-wheel drive unibody platform makes it less suitable for heavy-duty work. GMC has replaced the Safari with their Acadia 7-passenger crossover SUV for 2007.

Safety and Crash Testing

The Insurance Institute for Highway Safety (IIHS), which is known for its testing of vehicles and results that are often shown on NBC's Dateline television news program, gave the Astro a "poor" rating in 1996 because of what by all appearances was a horrifying display of structural failure in the Institute's 40 mph (64 km/h) crash test into a fixed, offset barrier. The underbody of the test van buckled, pitching both front seats forward and shoving the crash dummy into the dashboard and steering wheel, leading the Institute to comment that "[t]he collapse of the occupant compartment left little survival space for the driver." See detailed crash test information, including photos illustrating the Astro's structural collapse

In testing performed by the National Highway Traffic Safety Administration (NHTSA), however, the Astro and Safari fared better, improving from a single-star rating in 1990 to a three-star (driver) and four-star (passenger) rating by 1999. In side impacts, the Astro and Safari both received the highest, five-star rating in every year that the test was administered.

Popularity with modifiers

Chevy Astro modified with the addition of an operable Train horn and bell.

In addition to their popularity as conversion vans, the Astro and Safari both have popular followings with "back yard" modifiers. Modifications are both street and off-road. Some vans have the original 4.3L Vortec V6 engine replaced with a small-block V8 engine, such as the Chevrolet 350 engine. This switch is simplified because the 4.3L V6 is based on the GM small-block V8, and most of the factory drivetrain components can be reused.

Because of its truck based design, the Astro also is popular with some off road and camping enthusiasts. The combination of a powerful drivetrain, large cargo and passenger space, all-wheel drive, and stock G80 locking differential for the rear axle facilitate off road modifications. The suspension can be lifted, allowing larger tires and clearance with relatively small changes in exterior appearance. Overlandvans.com is a specialty company that provides specific suspension lift kits for all models the Astro van.