Outside Door Handles May Break on Chevrolet Astro

The outside door handles are prone to breaking—all doors are affected by this condition.

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Average mileage: 142,106 (13,115–258,000)
16 model years affected: 1990, 1991, 1992, 1993, more1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
72 people reported this problem
31 people shared problem details
2003 Chevrolet Astro175,000
handle broke can open back door
2005 Chevrolet Astro100,000
Both door handles broken....have ordered new ones. Seems to me another Government Motors (GM)design flaw..!! Can't wait for Nomobama care to start up...(once we can ACTUALLY sign up for it)...on that gubmnt' web site..!!
2003 Chevrolet Astro170,000
Back door handle stopped working.
1995 Chevrolet Astro105,000
I had the same problem with the driver's door. You can buy the replacement handles at the auto parts store. I followed the instructions in my Haynes manual with some success. It took myself longer to than what the instructions stated, and I had to disassemble the lock assembly to put everything back together. This part wasn't apart of the instructions.
1996 Chevrolet Astro150,000
Every Astro van we've used in our business has had major issues with door handles breaking. '91,'93,'96. Chevrolet needs to quit using cheap pig iron to make these; we've cleaned out area junk yards of their chevy astro door handles. Not so hard to fix, but pain in butt to find used. Have tried new replacements and they are just as inferior.
Door handle busted. Am replacing it now
1998 Chevrolet Astro125,000
Door handles broke.....all of them.
2004 Chevrolet Astro146,000
This is a common problem in Chevys. My family has owned several Suburbans & Chevy trucks with the same problem. The issue is not the door handle itself, but the spring that releases the door wears out, causing passengers to pull again and again on the handle because the door is hard to open. You can replace the handle, but without replacing the spring, it will happen again.
1990 Chevrolet Astro119,000
Door handles front doors both broke off
Front power locks quit working
door handle of driver side is broken
1993 Chevrolet Astro206,452
Outer door handle broken and rear seal on tranny leaks
2002 Chevrolet Astro168,000
door handle broke at the usual spot. I open my door from the inside now.
2002 Chevrolet Astro175,000
Driver's door handle broken. Could not install top nut, so I left it off. 20000 miles later the replacement handle is still doing OK.
240000 miles. Driver handle replaced twice
1994 Chevrolet Astro158,000
Door handles brake or inside rods come apart
same problem also my electrical windows don't work
1995 Chevrolet Astro100,000
I have replaced the driver outside door handle 4 times. Now I just let it stay broke and climb through passenger side....annoying! !!!!
The handles on my chevy astro 1994 they broke and the setup on the inside nobody seems to be able to repair in a way that it lasts.
Door handle has been broken 1/2 way a few years after I purchased the van. I must say even though one side of it broke the other side has not broken off and this is the drivers side.
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