2003 Chevrolet Astro: fire, smoke or burning smell

Filed May 17, 2011 · Electrical · CA

2003 chevrolet astro van. Consumer states the steering knuckle/arm is designed in a way that causes it to come into contact with a wiring harness when the vehicle is turned to the left *tgw over a period of time, the constant contact damaged the wiring harness and allowed the steering knuckle/arm to touch the wires inside the wiring harness. The end result caused damage to other wires. The consumer stated the problem started in february 2011 when making a left turn would sometimes cause the radio and the AC to die. The ABS light and brake light would also come on and the brake pedal would sink to the floor. The dealer was unable to duplicate the problem. Two weeks ago, while pulling out of a parking space, everything died. The engine would not restart and nothing electrical worked. The consumer was unable to exit the vehicle and there was a smell of burning wires. The consumer was finally able to manually push up the door locks to exit the vehicle. *jb the consumer stated he discovered a tsb and found the steering knuckle was not the source of the problem, but the battery cable retaining clips were not properly secured in their retaining holes in the engine cradle frame below the engine oil pan. As a result, the battery cable made contact with the steering linkage components and rubbed through the insulation on the cable. Updated 06/01/11

Filed Apr 25, 2011 · Electrical · 80,246 miles · CA

Potentially dangerous defect in the 2003 chevrolet astro van. The steering knuckle/arm is designed in a way that causes it to come into contact with a wiring harness when the vehicle is turned sharply to the left. Over a period of time, this constant contact damages the wiring harness and allows the steering knuckle/arm to touch the wires inside the wiring harness. The wiring harness is connected directly to the battery so the end result is damage to other wires also sheathed in that wiring harness. Two weeks ago, while pulling out of a grocery store parking space, everything died. The engine would not re-start and nothing electrical worked, from the door locks to the radio. Everything was dead. We could smell burning wires and tried to get out of the vehicle. Because the doors were locked we could not get them open. We had to manually push up our door locks; each of us pushing up the lock of our own door, so that we could get out of the vehicle. Since then when the problem occurred, additional issue was that the ABS light and brake light would come on and the brake pedal would sink to the floor. We came close to rear-ending someone several times. On april 23, 2011, we showed the damaged wiring harness to the mechanic at the chevrolet dealership. Within two hours, we received a call to let us know the electronic control module (ECM) and the anti-lock brake (ABS) module had been damaged. Both had to be replaced at a cost of over $2,100. We contacted general motors customer service this morning. Their response was that they considered this issue to be caused by ?normal wear, based upon the age of the vehicle.? We disagree with their findings. Concern is that this defect can cause damage to important safety items, such as the brakes and door locks. The area of the wiring harness that is coming into contact with the steering knuckle/arm should either be moved or better protected. We don't want other drivers injured.

Filed Aug 31, 2010 · Electrical · 78,000 miles · CO

2003 chevrolet astro van. Drove vehicle without incident on august 1, 2010. Monday morning august, 2, 2010 battery was dead (purchased new february 2010). Replaced with new battery on august 2, 2010. First connected the positive cable. Attempted to connect negative cable. Negative post terminal sparked and battery cable got very hot. Disconnected battery cable. Inspected fuses. All good. Trace visible portions of positive cable to fuse box, alternator, and starter. No indication of grounding. Contacted mechanic who on august 14, 2010 performed test on fuse box, alternator, and starter. All good. Mechanic thoroughly traced positive cable. Discovered short located at the passenger side of the engine behind the steering linkage. Stated that cable sheath had been worn away by the rubbing of the tie rod and was grounding out on the body and that it was extremely fortunate that the vehicle had not caught on fire. I had to have the vehicle towed to chevrolet dealership and had cable replaced.

Filed Nov 14, 2005 · Brakes, Electrical · 30,900 miles · TX · fire

On september 9, 2005 my 2003 chevrolet astro van exploded and caught fire in a parking lot. The fire dept. Arrived and put out the fire; the firemen disconnected the battery cable. The van was towed to huffines chevrolet in plano, tx. The cause of the incident according to the chevrolet mechanics is as follows: 1) every time the steering wheel was turned, the tie rods etc. Would chafe against a bracket on the chassis that held down a battery cable. 2) eventually the bracket failed. 3) the battery cable arced against the brake line. 4) the brake line ruptured spraying hydraulic fluid over the hot engine manifold. 5) the ensuing fire burned through, among other things, the A/C hose carrying freon. 6) when the A/C hosed was severed, the freon gas escaped causing the loud explosion that we heard some distance away. 7) the smoke that we saw in the air was actually the escaping freon gas. All was supposedly repaired in three weeks. On november 8, 2005, the brakes failed while under way. The chevrolet mechanics stated that the cause of the brake failure was traced to a small pinhole caused by the arcing battery cable several weeks ago. Eventually the entire brake line failed. If this story seems preposterous to you, it does to me too but this is the story we got from chevrolet. In my opinion, my 2003 chevy astro van suffers from a fatal flaw in design and/or manufacturer. It is unsafe and should be taken off the road forever.

Filed May 23, 2005 · Electrical · NY · 2 injuries

Consumer stated that both she and her 2 year old child got burned by the interior bulb. It overheated and melted the housing around it. Consumer's husband stated that it may have been a electrical wiring problem, and was afraid that the vehicle may catch on fire. *ak