Chevrolet Astro (1995-2005): How to Remove the Bumpers

Production Years and Main Generations

The Chevrolet Astro is a minivan produced from 1985 to 2005. Over two decades, the model underwent several upgrades while retaining its recognizable design.

  • First generation (1985–1994) – Debuted as a compact van and minivan, available in rear-wheel and all-wheel drive configurations.
  • Second generation (1995–2005) – Featured updated styling, improved safety, and more powerful engines.

Production ended in 2005 due to declining demand for such vehicles and the market shift toward more modern minivans and crossovers.

 

Names and Modifications

The Chevrolet Astro was sold under different names depending on the market and trim:

  • Chevrolet Astro – The standard version for the U.S. and Canada.
  • GMC Safari – A nearly identical variant under the GMC brand, differing only in the grille and some trim details.
  • Chevrolet Astro Van – The name most commonly used in everyday references.

There were also cargo versions, the Chevrolet Astro Cargo, without rear seats, intended for commercial use.

 

Model Overview

Design and Construction

The Astro stood out with its body-on-frame construction (unusual for minivans) and rear- or all-wheel-drive layout. This made it more durable and suitable for hauling cargo but less comfortable than contemporaries like the Dodge Caravan.

 

Engines and Transmissions

Throughout its production, the Astro was equipped with gasoline V6 engines:

  • 4.3L Vortec V6 (the primary engine from 1985, producing 150 to 200 hp depending on the model year).
  • In early years, a 2.5L Iron Duke I4 was offered, but it proved too weak for the heavy van and was quickly discontinued.

Transmissions – 4-speed automatic or 5-speed manual (rare).

How to Remove the Front Bumper

  1. Open the hood.
  2. Under the hood, unscrew the bolts securing the radiator grille.
  3. Below the headlights, remove two bolts on each side and detach the turn signals.
  4. Inside the turn signal openings, remove one bolt on each side and take off the radiator grille.
  5. Beneath the grille, pull out five push pins securing the upper part of the front bumper.
  6. Remove three push pins (inserted from bottom to top) on the front face.
  7. Turn the wheels to the side.
  8. In the wheel arches, unscrew one bolt on each side (fastened from bottom to top) securing the corners to the fenders.
  9. Remove one bolt on each side securing the lower part to the brackets.
  10. With an assistant, carefully pull the bumper forward (watch for wiring).
  11. Disconnect any electrical connectors (if present).

Chevrolet Astro II Radiator Grille Fastening Diagram (1995-2005)

Chevrolet Astro II Front Bumper Mounting Diagram (1995-2005)

How to Remove the Rear Bumper

⇒Useful tips on how to remove the bumper and not break anything.⇐

  1. From underneath, unscrew three bolts on each side securing the brackets to the body and one nut on each side attaching the rear bumper sides to the side brackets.

Chevrolet Astro II Rear Bumper Mounting Diagram (1995-2005)

Interior and Features

The Astro offered three interior configurations:

  • Passenger minivan – Up to 8 seats, sliding doors, optional third row.
  • Cargo version – No rear seats, reinforced flooring.
  • Luxury trim – Leather, air conditioning, audio system.

Over time, the model gained ABS, airbags, and other safety features, but it never reached premium technology levels.

 

Interesting Facts

  • Popular in films and TV – The Astro frequently appeared in 1990s–2000s movies and series, such as Six Feet Under and Supernatural.
  • A tuner favorite – Thanks to its body-on-frame construction and powerful engine, the Astro was used for custom builds, including lowriders and campers.
  • Military service – Some Astro/Safari models were used by the U.S. and Canadian armies as staff vehicles.
  • Long production run – 20 years without major platform changes.
  • Competitor to Japanese minivans – In the 1980s, GM marketed the Astro as an alternative to the Toyota Van and Nissan Van, but by the 2000s, it was outdated.

 

Conclusion

The Chevrolet Astro is a classic example of late-20th-century American automotive engineering: rugged, simple, yet full of character. Despite declining sales in its final years, it remains a cult favorite among retro van enthusiasts. Today, the Astro is valued for its reliability, ease of repair, and unique design, which stands out in the modern market.