ChevroletAstro 4WD2002Overview/chevrolet/astro-4wd/2002/base/

2002 Chevrolet Astro 4WD

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Astro 4WD.

Transmission Automatic 4-spd

The 2002 Chevrolet Astro 4WD is rated by the EPA at 20 city/23 highway/21 combined mpg and is paired with an Automatic 4‑spd transmission. Owner records show 83 total complaints, with the predominant issue in Service Brakes, Hydraulic, and three recall actions documented. Within the 1990‑1993 complaint history, the 2002 model sits near the lower‑end of the range, reporting fewer complaints than the 1993 peak of 166 but more than the 1990 low of 80.

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy20/23/21 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 78 · 600 CCA battery, OE oil filter 12731175. Note the factory fuel filter is now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 78 · 600 CCAOEM · verified
Tire sizeP215-75R15OEM · verified
Wheel / rim6-, 6.5-J inOEM · verified

OE service part numbers OEM · verified

Engine oil filter12731175
Engine air filter19259086
Fuel filter25171792 discontinued
Spark plug12681665
Front wiper blades15184702
Serpentine belt12576572 alt 19355374
Thermostat12632948 alt 12551507

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length189.8 in
Overall width77.6 in
Overall height75.2 in
Wheelbase111 in
Curb weight4202 lb
Track (front / rear)65 / 65.4 in

Ratings & economy EPA / vPIC

EPA city / highway / combined20 / 23 / 21 mpg
Drivetrain4-Wheel or All-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine SYNTHETIC · 75W-90 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 18.0 ft-lbs. The firing order is 1-6-5-4-3-2.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear OilSYNTHETIC · 75W-90 · GL-5
Differential Gear Oil Capacity4.5 qt

Engine torques

Crankshaft Pulley and/or Damper Bolts74 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Valve Cover Bolts8.85 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)74.0 ft-lbs
Leaf Spring to Chassis Bracket74.0 ft-lbs
Leaf Spring to Rear Shackle74.0 ft-lbs
Leaf Spring Rear Shackle to Chassis Bracket103.0 ft-lbs
Lug Nuts100 ft-lbs
Transfer Case Fill Plug15.0 ft-lbs
Transfer Case Drain Plug15.0 ft-lbs
Front Wheel Hub147 ft-lbs

Ignition

Cylinder Firing Order1-6-5-4-3-2
Spark Plug ManufacturerAC Delco
Spark Plug Gap0.060 in
Spark Plug Torque11-14 ft-lbs

Battery & A/C

RefrigerantR134a
Oil GroupPAG
Oil Type46
Standard BCI Group Number78
Standard BCI Cranking Performance600 cca
Optional BCI Group Number78
Optional BCI Cranking Performance770 cca

Service checks

Pressure Test20 psi
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature188-206 °F
Fuel Pump Pressure Minimum62.0 psi
Key ON Engine OFF (KOEO)55-62
RPM45-59 @ Idle rpm
Engine Compression100
Engine Compression100 Minimum psi

Brakes

Torque to Knuckle38 ft-lbs
Torque to Knuckle38 ft-lbs
Minimum Pad ThicknessFront: 0.030; Rear: 0.030 specification
Drum Runout Limit0.006 in
Drum Nominal Diameter9.5 in
Drum Maximum Machining9.56 in
Drum Discard at-or-over9.59
Rotor Max Parallel Variation0.001 in

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 100,000 mi; coolant at 150,000 mi. The big-interval services (at 150,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 miAxle Shaft Oil Seal (inspect) · CV Joint Boot (inspect) · Differential (inspect fluid level) · Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
At 15,000 miEngine Air Filter Element (inspect)
Every 30,000 miEngine Air Filter Element (inspect) · Engine Air Filter Element (replace) · Fuel Filter (replace) · Wheel Bearing (repack)
Every 50,000 miTransfer Case Assembly (drain & refill) · Transmission Fluid & Filter (replace)
Every 60,000 miAccessory Drive Belt (inspect)
Every 100,000 miPCV Valve (inspect) · Spark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 miEngine Coolant System (drain, flush & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Owner complaints about the 2002 Chevrolet Astro 4WD lead in one area — the service brakes, hydraulic, 16 of 83 reports (19%), well ahead of the next concern. None of this vehicle's 3 recall campaigns target the service brakes, hydraulic, so those reports read as owner-reported wear-and-tear rather than an acknowledged defect. 9 of the reports describe a crash and 3 a fire — a small share of the total, but worth weighing against the service brakes, hydraulic pattern above. These are tallies of what owners actually reported to the federal government, not an editorial score — and higher-selling models naturally rack up more reports.

3
Open recalls
NHTSA campaigns
0
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
83
Owner complaints
9 involved a crash · 3 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 83 complaints on record, top 8 components.

Service Brakes, Hydraulic16
Electrical System8
Tires6
Seat Belts6
Power Train6
Vehicle Speed Control5
Exterior Lighting4
Air Bags3

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 3 campaigns on record for this vehicle.

06E043000Fuel System, GasolineReported 19/05/2006

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18… Remedy: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION…

05V099000Exterior Lighting:Brake Lights:SwitchReported 14/03/2005

ON CERTAIN MINIVANS, THE MULTIFUNCTION SWITCH MAY DEVELOP AN OPEN CIRCUIT CONDITION IN THE STOP LAMP OR HAZARD LAMP CIRCUIT THAT RESULTS IN THE STOP LAMPS AND HAZARD LAMPS BEING INOPERATIVE. Remedy: DEALERS WILL REPLACE THE HAZARD WARNING FLASHER SWITCH AND APPLY SPECIAL GREASE TO THE CONTACTS AT THE TIME OF INSTALLATION OF THE MODULE FREE OF CHARGE. THE REPAIR WOULD BE USED…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Astro 4WD. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

Does the 2002 Astro 4WD have open recalls?

NHTSA lists 3 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Astro 4WD get?

EPA figures are 20 city / 23 highway / 21 combined mpg.