1991 Chevrolet S10 Problems

What owners report

Owner complaints for this model year center on the antilock brake system: drivers describe a pedal that sinks toward the floor, a brake warning light that stays on, and longer stopping distances, often in wet, icy or loose-surface conditions. Other recurring reports involve dashboard electrical failures and underhood fires, seat belts that will not stay latched, steering and front-suspension hardware, and fuel tank leaks from corrosion at the seams. Reported mileages are mostly high, consistent with a truck of this age, and many filings come from the late 1990s and early 2000s.

1. 1
   Brakes

   ABS pedal to the floor, long stopping distance

   • 66 complaints (38%)
   • typically at 6.8 yrs old
   • 12 mention a crash, fire or injury
   • filed 1995–2014

   Complaints describe the brake pedal travelling to the floorboard when applied, with the truck continuing to move and stopping only after pumping the pedal. Several owners say the antilock and brake warning lights came on and stayed lit while normal braking felt reduced. Some report that dealers could not identify a cause, replaced the master cylinder, pads, rotors or calipers without resolving it, or told the driver the behavior was normal for ABS. A number of filings mention that recall 99V193000 did not cover their vehicle because of build configuration or VIN. Described across a wide mileage range, frequently in slippery conditions such as ice, rain or loose pavement, and sometimes on the first stop after a cold start.

   Recall 99V193000

   What to check: Ask whether the ABS switch covered by recall 99V193000 was replaced, and confirm the brake warning lamp goes out after startup. A test drive on a wet or loose surface can show whether the system engages normally.

   2 excerpts from owner complaints in NHTSA records

   “Applied brakes hard in both instances to avoid collision . The instance in 98 it was raining but the truck should have slowed faster . It was as if ii hadn't appied the brakes but a little . But I was pressing hard . In the occurance in 99 I was in a construction zone . There was a little loose pavement material on the road , as they were cutting out pavement 100 yards up the road .I applied the brakes in a fast stop as the traffic had stopped in front of me . And the truck did not stop as fast as it should of . …”

   NHTSA complaint #709699, filed 1999-08

   “Ea94038; when the roads are slippery or going over a railroad track, the ABS braking system malfunctioned, causing extended stopping distance which caused rear end accidents. Dealer cannot determine problem. Also when carrying a load in the rear of the vehicle. When braking, the driver's seat will move forward where the occupant will hit the steering wheel.”

   NHTSA complaint #821079, filed 1998-02
2. 2
   Electrical system

   Dashboard electrical failures and underhood smoke

   • 15 complaints (9%)
   • typically at 6.0 yrs old
   • 8 mention a crash, fire or injury
   • filed 1995–2001

   Owners describe smoke or flames from the dash or engine bay, in some cases with the alternator or dash wiring involved and the digital instrument cluster going dark. Other complaints report the electronic dash losing the fuel, temperature, oil pressure and tachometer readouts while the speedometer continues to work. Complaints link some failures to vibration, and interior smoke was reported before the dash stopped working. Reported at various mileages on vehicles of this age, with several filings describing failures while driving or overnight.

   What to check: Inspect the dash and engine-bay wiring for chafing, melted insulation or scorching, and check that all instrument gauges read correctly with the key on. Ask whether the alternator or any dash wiring has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The antilock brake light is on all the time, the regular braking abilities are not affected, but the antilocking capabilities are gone. The digital dash guages do not work, the only lighted items that work are the odometer & the speedometer ( no fuel guage, no engine temp, no oil pressure, no tach, no amp meter).”

   NHTSA complaint #730927, filed 2000-09

   “While driving, digital readout electronic dashboard blacked out, causing no lights/speedometer/odometer/engine temperature/fuel gauges and rmp readout due to vibration which is unique in trucks.”

   NHTSA complaint #806914, filed 1996-12
3. 3
   Body and structure

   Steering and front suspension hardware looseness or breakage

   • 7 complaints (4%)
   • typically at 8.6 yrs old
   • filed 1995–2000

   Owners report the intermediate steering shaft loosening at the coupling, steering columns that feel loose or move in the opposite direction when turning, and steering wheel nuts coming loose so the wheel tilts. Others describe a front lower control arm bracket separating from the frame and a stabilizer bar bracket breaking and striking the tire, with owners stating the failures did not follow a collision or curb strike. A recall addresses the steering shaft coupling hardware on certain vehicles. Reported mostly on higher-mileage trucks; complaints do not give a consistent mileage figure.

   Recall 96V195000Recall 90V193000

   What to check: Have a shop check the steering shaft coupling, column play and front control-arm and stabilizer mountings for looseness, cracks or prior repairs, and ask whether recalls 96V195000 and 90V193000 were performed.

   2 excerpts from owner complaints in NHTSA records

   “The left front control arm mounting bracket broke away from the frame. This vehicle has never been in an accident. The failure was not due to hitting any object such as a curb or pothole. It appears that the failure was due to fatigue.”

   NHTSA complaint #709413, filed 1999-07

   “Steering failure was catastrophic. Vehicle veered suddenly in heavy traffic. Managed to control vehicle, slow down and exit. Universal joint failed when nylon connectors, approximately 1/4 inch thick, shattering without warning.”

   NHTSA complaint #539080, filed 1998-07
4. 4
   Seat belts

   Seat belts that will not stay latched or retract

   • 16 complaints (9%)
   • typically at 4.9 yrs old
   • 3 mention a crash, fire or injury
   • filed 1995–2004

   Complaints describe the driver belt releasing while the truck is moving or standing still, and belts that will not extend or lock into the buckle. One owner reported that the front belts had behaved this way since the vehicle was new, and a dealer response described it as not a safety problem. Another filing says rear belt buckle release buttons stick and the belt will not lock. Reported over long periods of ownership; several complaints do not state mileage, and one notes the problem was present from new.

   What to check: Fasten and release each belt several times and tug sharply on the shoulder section to confirm it locks. Check that the buckle release returns freely and that the belt webbing retracts.

   2 excerpts from owner complaints in NHTSA records

   “Driver seatbelt comes loose while vehicle moving and while sitting still. Talked to dealer in pickens recently same story not a safety problem. This problem has been present since the vehicle was new. The driver belt got to where would never latch. Passanger belt would not extend most of the time not used for that reason.”

   NHTSA complaint #705696, filed 1999-04

   “Vehicle was involved in a collision. Upon impact, restraints did not retract, causing major injuries. Dealer has been notified. The consumer after being examined by a physician believes he suffered major injury.”

   NHTSA complaint #886068, filed 2001-04
5. 5
   Fuel system

   Fuel tank leaks from corrosion at the seams

   • 9 complaints (5%)
   • typically at 6.8 yrs old
   • filed 1995–2003

   Complaints describe gasoline leaks from the fuel tank, in several cases traced to corrosion and pinholes at the tank seams. Owners attribute the rust to moisture trapped by the plastic skid shield or by a cover holding water against the tank, and one reports a leak just above the seam. One filing notes a fuel tank sender seal shipped out of position, which is the subject of a recall. Reported on older, higher-mileage trucks, often after years of use in damp conditions or with the shield retaining debris.

   Recall 91V108000

   What to check: Look at the tank seams and the area behind the skid shield for rust, damp debris or fuel staining, and check for a gasoline smell after parking. Ask whether the tank or sender seal has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Often when making left turns spare tire carrier will unlatch by itself. Owner has tied the carrier to keep it from flying open. Also, fuel tank had a serious leak just above the seam in the rear of the tank.”

   NHTSA complaint #863493, filed 2000-06

   “Skid pad cover is holding water against fuel tank and causing corrosion which leads to fuel leak from fuel tank. Dealer was notified. Feel free to provide any further information.”

   NHTSA complaint #898397, filed 2001-10

Buying note. Because the sampled complaints concentrate on braking performance, check the ABS warning lamp and brake feel on a wet-road test drive, and confirm whether recall 99V193000 applied to the specific truck. Budget for a close inspection of the fuel tank, wiring and front-end hardware on any high-mileage example.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.