Transmission gave out at 200,000 KM - replaced with a used one, which has performed flawlessly.
Engine gave up the ghost at 240,000 KM - replaced with a rebuilt short block, which has given no problem.
Idler arm replaced recently.
Recently replaced front rotors, bearings, calipers and pads, due to normal wear.
I've replaced the door handles on both the driver's front door and the passenger side front door twice, but they're reasonably easy to fix, and cheap.
Recently replaced the radiator... took just an hour of enjoyable wrenching, and it was done!
Wow, we could not be happier with this van!! We've put plenty of miles on it with our four kids, and it still looks and runs good! We bought it in B.C., in Canada, and live just south of the border, in Lynden, WA - hence the Kilometers on the odometer.
We think the previous owners were good at washing and vacuuming, but not so good at maintenance, as they most likely never changed the oil. Not long after buying it, we discovered it was burning through oil at a prodigious rate, but the trusty 4.3 kept chugging right along. When it got embarrassing to drive due to the smoke, we replaced the engine, which wasn't too expensive.
One item we've been surprised by is the durability of the interior. We've had four kids grow up in the van, with all their friends, and there are no rips yet. Even the carpet, which is burgundy in color, looks good.
When we get a new vehicle, I'll probably keep this thing myself for my own use. I'll lower it, put in a 350, and have a little fun with it!
I've come to know and love the simple, but reliable mechanicals of this vehicle... easy to work on, and obviously good in design!
I'm the original writer of the above review. The van now has 330,000 Km, and we're thinking about replacing it with another Astro Van. What a great van this has been. We will miss it when we sell it. Just last week, it started overheating, so I replaced the water pump, and the thermostat (a rebuilt water pump costs just $19.99... can you believe it?!) Just 2 hours and I was ready for a test drive... running like a champ. We've had the van for 10 years now, and it still looks good. We should still be able to get a few bucks out of it, and some other lucky family should be able to get a few years out of it yet. I highly recommend these vans... they are simply a great value for the money!