Battery Cable problems of the 2003 Chevrolet Astro

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 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. 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.

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.

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.

I have a 2003 chevy Astro. The problem started in January of 2005. The volts meter started dropping. I took it to phil smith Chevrolet in lauderhill, florida. They did an electric diagnostic and found the alternator and battery to be bad. I changed the alternator and battery on my own. Vehicle still had same problem afterwards. I then took my vehicle back to phil smith Chevrolet, and they said that the battery cables were bad. I had them change them. The battery light was still coming on, and they said that it was okay, they just forgot to reset the light. Everything was okay, except for the battery light still coming on, until may of 2005. When I accelerate from a complete stop, my vehicle stalls out, but starts right back up. I then brought my vehicle to trapp Chevrolet in houma, la. They ran a diagnostic and said that the alternator was bad. So, I then changed the altenator again. I was still having the same problem. So I returned to trapp. They ran a diagnostic test again, and said that the fuel filter was out and distributor cap and rotor was out. I then changed the fuel filter, distributor cap, and rotor myself. I was still having the same problem. I then, returned to trapp Chevrolet, and they said that they cannot find the problem, and the mechanic has driven the vehicle and sees the problem, but cannot find the problem. If I want them to continue working to find the problem, I have to pay for another diagnostic test, even though they haven't found the problem to begin with.