The huge popularity of vanning and overlanding has really given the Astro van a whole new lease on life. It’s hot, as there’s very little else in the category for folks looking for a fairly cheap and compact AWD van. A Mercedes AWD Sprinter is mighty big bucks. I’m seeing more and more of these on the road, out in the boonies, and here in the neighborhood, like this one.
Doing a bit of research indicates that the basic drive train (4.3 V6/4L60e) is of course durable, although certain components like the fuel injection “spider” and other items are likely to need replacement at some point. Apparently the last model years (2002-2005) are the ones to have, as they have improved brakes (disc at the rear) and a few other upgrades. Swapping the fiberglass rear leaf springs for steel ones, and modest 2-4″ lifts are popular. Fuel economy is not so hot (14-17 mpg), which is well below what my much larger Promaster gets. And the Astro van’s AWD system isn’t true 4WD, and is not exactly Rubicon-ready, but it certainly can make the difference between getting stuck in soft sand or snow, or not.
Note: a rerun of an older post.
All Astros were built at the Broening Hwy plant in Baltimore which had been a GM factory since the mid ’30s.
I toured it once in 1979 when they were making Pontiac Gran Prixs and the like, they had just introduced some robots for body welding, but was impressed they still did lead filling of some roof seams. I believe when the Astro was discontinued the plant was closed and later demolished. One of my son ‘s friends had the aid version and it was a good vehicle for him, a mountain bike racer who would actually take it off road sometimes.
Fiberglass rear leaf springs? Now I have heard everything at least for me.
Corvettes used composite mono leaf springs since the 80’s both rear and front depending on the particular year. W-bodies and certain E bodies used them too.
Developed in the mid 80s in the UK by GKN Composite leaf springs were developed for the Freight Rover, (previously Leyland, later LDV ) Sherpa vans.https://www.aronline.co.uk/opinion/i-was-there/testing-on-sherpas/
My 93 Ford Ranger had composite leaf springs too
Yes, these were ‘AWD’, the transfer case was full-time and didn’t have a low range. I seem to remember the same one was used on the Olds Bravada. The ‘Central Point’ fuel injection system was reliable until it wasn’t. The individual injectors were grouped together in the top of the intake manifold and each had a small tube running down each intake port with a check valve on the end. The advantage was the nozzle was in the optimal position close to the intake valve. The disadvantage was the nozzle check valves tended to gum up and stick. The fuel pressure regulator was also located in the intake manifold, when it leaked the engine would run very rich, needless to say. By 1999 GM came up with an updated system that did away with the remote mounted injectors and had a better regulator that was very reliable. These engines also occasionally had leaking intake manifold gaskets, but overall they ran well and were usually good for 200,000+ miles with proper maintenance.
I’ve seen a few Astros done up like this in Central Oregon, as the smaller and cheaper alternative to a 4×4 Econoline and the way cheaper alternative to a Sprinter or Transit. These are also popular in Japan as a more sensibly sized alternative to the Dodge Tradesman
Seeing this almost makes me wish I had my ’05 back–ALMOST. I believe it was 2003 when the brakes AND wheels were upgraded to the 6-lug design that was shared with the GMT800 pickups & SUVs (Silverado/Sierra, Tahoe/Yukon, etc.).
The powertrain is pretty much bulletproof on these; it’s EVERYTHING else you have to worry about as the miles add up, electronics included. Mine went to 286k miles when the ECM failed & left me stranded on the road at 2:30 in the morning, and by that point some other things were going to need eventual replacement within the foreseeable future, including the OTHER culprit of my breaking down (the anti-theft system). A lot of work had been done to it already and I didn’t want to take any more chances, so 2 years ago a 2016 Ford Transit Connect took its place. The new van will do 90% of the work the Astro could (except trailer towing) but gets MUCH better fuel economy while doing it and besides having issues with the Hill Start Assist system has otherwise been trouble-free so far. Still, the Astro was a good if not PERFECT work/pleasure vehicle (what vehicle IS?) and as of May last year it’s still on the road. And indeed, there are plenty of others still around too.