1991 Dodge Grand Caravan Problems

What owners report

Owner complaints on this model year center on two very different themes: ABS brake hardware that keeps failing or is turned away at the dealer, and a fuel rail that develops leaks and drips onto the engine. Many of the sampled complaints concern long-running issues that owners tried to have corrected repeatedly, and several involve safety systems such as seat belt buckles and rear seat belt anchorages.

1. 1
   Brakes

   ABS hydraulic unit failures and brake pedal problems

   • 26 complaints (20%)
   • median 212,500 mi at 26.0 yrs old (4 state mileage, few)
   • filed 1996–2020

   Owners describe the ABS light coming on and then a loss of power assist or braking effect: the pedal goes stiff and needs heavy pressure, or it sinks toward the floor before the brakes engage. Several complaints say the ABS hydraulic unit or pump relay was replaced, and some say the failure returned after repair or that the dealer would not service it under the recall. Others report the ABS not releasing, so the van hesitates or refuses to move off after stopping. Reports span the whole mileage range in the sample, from around 66,000 miles to well past 280,000 miles, and many come long after the original sale.

   Recall 96V099000

   What to check: Ask whether the ABS recall work was done and whether the hydraulic unit has been replaced, and look for an ABS or brake warning light with the key on. A test drive should include firm brake application to check for a hard pedal or delayed engagement.

   2 excerpts from owner complaints in NHTSA records

   “The first repair we were charged with the replacement of the master cycl and the ABS piston assy and we were never told it had been recalled, they charged us for 5 pints of brake fluid and all parts totalling $494.51 to complete this job. Since they did not know about the recall. I really doubt they did the job correctly. The next occurrance explains the brake fluid. …”

   NHTSA complaint #701029, filed 1998-12

   “Andy lewis Dodge did not repair anti lock brakes on recalls they were hostile to me and my van was operable when left there. When I picked it up I had to have a wrecker take it home.the battery was dead and the antilock light continued to stay on. They never repaired the brake problem with the recalls. They are leaking now.”

   NHTSA complaint #10069998, filed 2004-01
2. 2
   Fuel system

   Fuel rail and injector leaks at the top of the engine

   • 15 complaints (12%)
   • median 159,986 mi at 14.4 yrs old (5 state mileage, few)
   • filed 1999–2009

   Complaints describe a strong gasoline smell and fuel pooling on top of the engine, traced to the fuel rail or its injector seals. Owners report the leak dripping onto valve covers, spark plugs and hot engine parts, and some say a mechanic warned them the fuel rail was cracked or separating near the connecting tube. Parts were reported as back-ordered, and in several cases the dealer or selling business would not cover the repair. Reported from roughly 74,000 to 189,000 miles in the sample, and several owners note the leak appears when the engine is cold.

   What to check: Smell for raw fuel around the engine bay after the van has sat, and look for damp or stained areas along the fuel rail and on the valve cover. Ask whether the fuel rail, injectors or their O-rings have ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I would like to know if my vehicle, a 1991 Dodge caravan with 3.3l v-6 engine is included in the leaking fuel recall (I.e. Fuel rail seals) here is the recall I researched for your reference: NHTSA campaign id number: 00v268000 fuel: fuel injection system manufacturer: daimlerchrysler corporation mfg. …”

   NHTSA complaint #10053142, filed 2004-01, 185,000 miles

   “I was on my way home with my four kids when I noticed a strong smell of gas. When my husband got home I had him look at it to find out it was leaking gas from the fuel rail so bad that there was standing gas on the valve cover leaking into where my spark plugs are. I contacted the place I am buying it from and they refuse to fix it, unless I pay for it. Is there any recall in this problem?I see there has been many complaints same as mine.”

   NHTSA complaint #10144915, filed 2005-12, 154,033 miles
3. 3
   Seat belts

   Rear seat belt anchor hook releases from the floor

   • 16 complaints (12%)
   • typically at 6.5 yrs old
   • filed 1997–1998

   Owners of the middle-row right-side seating position report the seat belt anchor hook coming off the floor anchor, with the spring clip releasing or snapping inside out. Some say the clip was replaced several times and the problem returned. Others describe buckles that would not unbuckle or belts that would not pull out from the panel, and one owner reports the buckle sticking inside its cover so it would only partly latch. Most of the sampled accounts are from the late 1990s on vehicles with no mileage recorded; one owner describes repeated release while fastening the belt.

   Recall 97V149000Recall 97V148000

   What to check: Have someone sit in the middle-row right seat and pull firmly on the belt while looking at the floor anchor hook, and check that both front buckles latch fully and release cleanly. Ask whether the seat belt anchor and buckle recalls were completed.

   2 excerpts from owner complaints in NHTSA records

   “Drivers side seatbelt would not unbuckle. Problem area is buckle housing mark press. Consumer was unable to unbuckle the seat belt, after an hour he went to the dealership and they were unable to unbuckle it so they advised him to cut it off, they could not cut it off due to liability reasons.”

   NHTSA complaint #825698, filed 1998-07

   “The seat belt hook on the right side in the middle of the vehicle disengages from the metal floor anchor. The spring clip is not broken. Consumer has not taken the vehicle to the dealer. Please add further information.”

   NHTSA complaint #811557, filed 1997-04
4. 4
   Transmission and drivetrain

   Transmission locking in gear or refusing to shift

   • 12 complaints (9%)
   • typically at 8.0 yrs old
   • 1 mention a crash, fire or injury
   • filed 1997–2002

   Owners describe the transmission locking in drive or second gear, jerking forward when the throttle is applied, or refusing to move at all until the battery is disconnected to reset the controls. Some complaints involve repeated rebuilds or replacements at owner expense, and one owner says the vehicle would not exceed 30 to 40 mph after the transmission shut it down. Several of the sampled reports occur under 60,000 miles, with others spread through higher mileage.

   What to check: During a test drive, check that the van shifts up and down through all gears smoothly and will move normally from a stop when cold. Ask for service records showing whether the transmission was rebuilt or replaced and when.

   2 excerpts from owner complaints in NHTSA records

   “Around august 4, 2003, my Dodge Grand Caravan suddenly locked in second gear. I have replaced the filter and the transmission fluid. This did not fix the transmission. While asking friends if they knew any to fix the problem before I take it to a shop to be fixed, one of them print me the information about the chrysler ultradrive transmission report that is on your web site. I have got to my local Dodge dealer and they said that they have never heard of ultradrive transmission problem or recall. …”

   NHTSA complaint #10069919, filed 2004-01, 18,150 miles

   “Original transmission was rebuilt by dealership at our expense. Later, had to replace the transmission because of the same problem. Chrysler would not cover any of the expenses and we have never heard if any recall work was done for transmission problems.”

   NHTSA complaint #766442, filed 2002-08
5. 5
   Body and structure

   Liftgate strut bolts breaking and gate falling

   • 5 complaints (4%)
   • typically at 8.5 yrs old
   • 1 mention a crash, fire or injury
   • filed 1997–1999

   Owners report the strut mounting bolt at the liftgate shearing off, letting the gate drop unexpectedly, with one owner describing being struck. Another complaint says the dealer would not check for hairline cracks and would replace the bolt only once it had broken. A few owners note their vehicle was excluded from the liftgate recall by VIN even though the same part failed. Reports come from the late 1990s with no mileage recorded, on vehicles in regular use for several years.

   Recall 99V213000

   What to check: Open and close the liftgate several times and watch the strut attachment points for movement, rust or cracking around the bolts. Ask whether the liftgate strut recall was performed and whether the bolts have ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Liftgate bolt broke, causing liftgate to fall down, and may have caused injuries. There is a recall for 1992 Grand Caravan, recall 97v079000, but this vehicle is not included in the recall due to VIN although it has the same problem. Please provide further information.”

   NHTSA complaint #841203, filed 1999-06

   “Recall 99v-21 is for cracked liftgate bolts, dealer unwilling to check for hairline cracks and stated bolts could only be replaced if broken, consumer not satisfied (not pleased). Yh”

   NHTSA complaint #549559, filed 1999-10

Buying note. Given the age of these vans, condition and repair history matter more than the model year itself; ask for records on the ABS unit, fuel rail and transmission before buying. A careful inspection of the brakes, the fuel system and the liftgate and seat belt hardware is worth the cost on any example you consider.

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.