1991 Dodge Caravan Problems

What owners report

Complaints on this model year center on the anti-lock brake system: owners describe warning lights staying on, a hard or soft pedal, fluid leaks and, in some cases, loss of braking. Front seat belt buckles and anchors, liftgate struts and hinges, door and body seams, and transmission behavior are the other recurring themes. Many reports were filed years after purchase, so they reflect long-term wear on an older van as much as anything else.

1. 1
   Brakes

   ABS warning light, pump noise and brake fluid leaks

   • 214 complaints (35%)
   • median 130,000 mi at 15.3 yrs old (9 state mileage, few)
   • 12 mention a crash, fire or injury
   • filed 1995–2014

   Owners describe the anti-lock and brake warning lights coming on and staying lit, the ABS pump motor running when the brakes are not applied, a pedal that goes hard or soft, and brake fluid leaking near the hydraulic unit. Some report longer stopping distances or loss of braking and say the dealer found no stored codes or quoted a costly repair for the hydraulic assembly or a speed sensor. Several owners say they were told their vehicle was not covered by recall 96V099000 because of its VIN, even though the symptoms matched. Reports span a wide mileage range, from roughly 50,000 to over 180,000 miles, with many filed well after the warranty period.

   Recall 96V099000Recall 92V030000Recall 91V191000

   What to check: Ask whether the ABS hydraulic unit was serviced under recall 96V099000 and keep receipts; check the fluid level and look for seepage around the ABS pump and hoses, and confirm the warning lamp goes out after the bulb check.

   2 excerpts from owner complaints in NHTSA records

   “Lost my brakes for the third time in three years, due to evasive action I missed hitting a car but could not stop from hitting the curb and scrape a street pole, broke an axle and suspension parts all on thanksgiving.”

   NHTSA complaint #10016907, filed 2003-05, 183,000 miles

   “Re:transmission - I realize it is not safety related but thought you would like to know. Re:ABS warning light - dealer will do nothing unless a hard code is shown. The light stays on for days but as with an aching tooth, the pain sometimes disappears when visiting the dentist. Always on when I take it in but leaving the van a day or two at the dealer sometimes causes the light to go out for a short time.”

   NHTSA complaint #708231, filed 1999-07
2. 2
   Body and structure

   Liftgate and door hinges, latches and struts

   • 126 complaints (20%)
   • median 216,500 mi at 13.3 yrs old (3 state mileage, few)
   • 15 mention a crash, fire or injury
   • filed 1995–2004

   Owners describe rear hatch struts and hinge bolts breaking away from the body, so the liftgate drops or will not stay open, and hatch bolts that have sheared. Others report sliding doors jumping their track or falling, cracks in door frames and body seams spreading at the door, and paint peeling from the roof and hood. Some owners say the dealer told them the van was not covered by the liftgate recall. Mostly reported on vans with substantial use; where mileage is given it is around 100,000 miles or more.

   Recall 99V213000

   What to check: Open and close the liftgate and both sliding doors several times, watching the strut mounts and hinge bolts for looseness or cracks, and check the door frames and rear body seams for splitting; ask whether recall 99V213000 was performed.

   2 excerpts from owner complaints in NHTSA records

   “The tensioner and pulley to the power steering failed and so we replaced it already but would like you to know for other consumers. We have a question regarding the paint job. We know it is not a safety issue but my friends who have older cars don't have their paint coming off on their roof or hood. We can see other minivans around town with the same model and blue color paint peeling off also. And we are the only cars which have this problem. Please contact us regarding this problem. …”

   NHTSA complaint #749056, filed 2001-07

   “The passenger side front door is cracked at the frame and the door will not close securely. I have had it checked out at the body shop and was advised that it looked like a defect. I have contacted my local chrysler dealer, but all they did was look at the door and offered no information (of course!) I am wondering if this has happened to someone else? And if it is in fact a defect in workmanship. I am a single parent household with one vehicle and it is dangerous for my children to ride in the front seat in case the door shall fly open. …”

   NHTSA complaint #733049, filed 2000-10
3. 3
   Seat belts

   Seat belt buckles and anchors releasing

   • 103 complaints (17%)
   • typically at 5.7 yrs old
   • 3 mention a crash, fire or injury
   • filed 1995–2014

   Complaints describe front buckles that only partly latch because the release button sticks under its cover, belts that no longer retract or grab in a panic stop, and rear or middle-row anchor hooks that come unhooked from the body. Owners report the belt unlatching while in use and describe dealer responses ranging from 'not covered by a recall' to agreement that the anchorage design is poor. Reported across a range of ages and mileages, with many complaints filed in the late 1990s.

   Recall 97V148000Recall 97V149000

   What to check: Latch and pull each belt firmly, check that the release button springs back and that the belt retracts, and look at the rear center anchor hook for security; ask whether recalls 97V148000 and 97V149000 were completed.

   2 excerpts from owner complaints in NHTSA records

   “Front seat belt material unraveling, plastic broke, could fail in accident; middle seat anchor for passenger side seat belt worn, dealer agrees not good design, in event of accident, occupant would survive.”

   NHTSA complaint #800523, filed 1996-08

   “Ea-97-005, safety belt failure. Safety belt anchorage releases frequently when belt is in use. Purchased in nov of 91. The spring clip is broken. Dealer has not looked at problem.”

   NHTSA complaint #811411, filed 1997-04
4. 4
   Transmission and drivetrain

   Transmission erratic shifting and stalling

   • 52 complaints (8%)
   • median 92,405 mi at 14.5 yrs old (2 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1995–2014

   Owners describe revving without engagement when the van is cold or in wet weather, harsh or delayed shifts, sticking in a gear without decelerating, and sudden stalling while driving. Several report the transmission being replaced more than once, and some say dealer visits and manufacturer calls did not resolve the behavior. Typically reported between about 95,000 and 130,000 miles.

   What to check: Drive the van from cold, including a stop-and-go stretch, and note any delayed or harsh engagement; ask for transmission service records and whether the unit has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “While driving vehicle suddenly stopped. Took vehicle to a mechanic, and they put in a new transmission from chrysler. Less than 24000 miles, transmission went out again. Consumer has had 3 transmissions fail, and a forth one was being put in.”

   NHTSA complaint #864318, filed 2000-06

   “While driving 55 MPH vehicle stalled. Driver was able to restart vehicle, an dtook it to the dealer for inspection. Mechanic determined that the transmission needed to be replaced and replaced it three times.”

   NHTSA complaint #10115812, filed 2005-03

Buying note. On a van this old, condition and service history matter more than the model's record: have the brakes, belts and liftgate hardware inspected before purchase and check the fluid levels and lines. Ask for receipts showing whether the ABS and seat belt recalls were completed on the specific vehicle.

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.