Vehicle involved 1997 Chevrolet Astro 1. seat recliner was being used when the handle broke off. The seat remained in the position established when the handle broke. Started driving the van and suddenly the seat back went completely flat. The driver was able to hang on to the steering wheel and maintain control of the vehicle although the vehicle did wander into the left lane during the incident. 2. I investigated the failure and found the plastic handle was intact, however the metal pivot piece that engages the serrated locking plate failed. This pivot piece also contains the torsion spring that locks the plate when the handle is not being actuated. The design is not intrinsicly safe in that the locking plate is pushed upward by the spring to secure the seat. As long as there is pressure on the seat the mechanism will stay engaged. Without a load on the seat, the locking plate can drop free due to gravity and the seat will recline backward to the full flat position. Examination of the pivot piece appears to show a crack started where the spring is secured and the crack propogated through the piece due to fatique and vibration until failure occurred. 3. the seat was locked into a permanent position using high strength fasteners and existing holes in the seat frame. Additionally, the locking plate was engaged and also pinned into place to further secure the seat. The reclining feature of the seat is no longer functional. I retained the broken adjustment handle with pivot piece.

- Kalamazoo, MI, USA

Slowed down for traffic on interstate; vehicle stopped; semi rearended vehicle #2 & that vehicle rearended Astro, causing driver's seat to collapse backwards; view was obstructed; took to mechanic & noticed bolts sheared off & pulled out of threads; have parts.

- Colorado Springs, CO, USA