1991 Jeep Wrangler Problems

What owners report

Owners of this 1991 Wrangler most often report parking brakes that release on their own after the vehicle is parked, and fuel leaks from the tank, sending unit gasket, or fuel rail. Complaints also describe seat belts that will not stay latched or retract, brake hoses rubbing, and occasional stalling or clutch problems. Many of these reports are tied to safety recalls from the 1990s, and several owners say the repairs were never completed because parts or coverage were not available.

1. 1
   Brakes

   Parking brake releases on its own

   • 13 complaints (17%)
   • median 115,000 mi at 12.5 yrs old (3 state mileage, few)
   • 4 mention a crash, fire or injury
   • filed 1995–2024

   Owners describe setting the parking brake and later finding the vehicle rolling, sometimes after a pop or without any warning, including on hills and while the vehicle was unattended. Several reports mention damage after the vehicle rolled into another car, a curb, or water, and some owners say a foot brake assembly replaced under recall did not stop the problem. A recall (02V041000) describes a parking brake that can self-release on manual-transmission vehicles; complaints also describe dealers refusing or delaying the repair, or telling owners that parts were unavailable. Reported across a wide mileage range, from about 82,000 to 145,000 miles, with no clear weather pattern.

   Recall 02V041000

   What to check: Ask whether recall 02V041000 was performed and whether the parking brake holds firmly on an incline with the engine running. Test it on a slope before buying, and consider having the brake assembly inspected.

   2 excerpts from owner complaints in NHTSA records

   “The consumer had been waiting for parts regarding a recall for 3 months for the parking brake, however the dealer did not return the consumer's phone calls.”

   NHTSA complaint #10017547, filed 2003-04, 145,000 miles

   “Emergency parking brake releases on it own when not attended, vehicle will roll away. Contacted dealer. . Consumer stated the emergency brake released 4 times when the vehicle was unattened, consumer purchased a new foot brake assembly on jan 27,1999 and installed it, however the problem reoccured.8jb”

   NHTSA complaint #8005489, filed 2002-03
2. 2
   Fuel system

   Fuel leaks from tank or sending unit gasket

   • 21 complaints (28%)
   • median 88,000 mi at 20.4 yrs old (2 state mileage, few)
   • filed 1995–2015

   Complaints describe fuel pouring or leaking from the tank area, often traced to a cracked gasket at the fuel tank sending unit or a cracked plastic tank, and in some cases recurring after the tank was replaced. One owner reports a leak at the plugged end of the fuel rail near the exhaust manifold, and another describes fuel spilling out during refueling. A recall (94V106000) covers a sending unit gasket that can crack and allow fuel and vapor leaks; several owners say the dealer told them their vehicle was not covered or that the repair was not done. Reported from roughly 70,000 to 115,000 miles, and also described as recurring over many years on the same vehicle.

   Recall 94V106000

   What to check: Check for a fuel smell around the tank and under the hood after refueling, and ask whether recall 94V106000 was completed. Look for stains or wet spots at the tank corner and the fuel rail.

   2 excerpts from owner complaints in NHTSA records

   “My fuel tank is the problem. It first started leaking in 1991 when I first got my Jeep. It was repaired. Then it started leaking again in 1996, and I took in, it and the recall covered that repair. Then again in 1998, the tank leaked again. Same problem each time. They said it was the fuel send unit, but each time they had to replace the gas tank completely. The only time the manufacturer paid for it was when I took it in under the recall. The other times, I paid for it. Because it is the gas tank, it could easily lead to fatalities. …”

   NHTSA complaint #704685, filed 1999-03

   “I'm the original owner of a stock 1991 Jeep Wrangler with 2.5 liter engine at 106,000 miles. The fuel rail has failed and is leaking at factory installed plugged end of the rail at the opposite end from the fuel pressure regular. The leak is between the plug and the rail. This should have been a brazed sealed end or a threaded plug instead of a compression fitting of a plug. The leak produces a spray of gasoline near the exhaust manifold which could lead to a fire. …”

   NHTSA complaint #10180888, filed 2007-01, 106,000 miles
3. 3
   Seat belts

   Seat belts will not latch or retract

   • 11 complaints (14%)
   • typically at 5.9 yrs old
   • filed 1995–2005

   Owners report buckles that will not stay latched or come unlatched during hard braking, leaving the occupant unrestrained, and shoulder belts that do not retract and get caught and frayed in the door. Some say the problem started on the driver's side and then appeared on the passenger side, and that the dealer was notified but did not correct it. Described in complaints filed from the mid-1990s onward, with no mileage stated in most reports.

   What to check: Pull each belt out fully and let it retract, then latch and tug each buckle to confirm it holds. Look for fraying where the belt passes through the door opening.

   2 excerpts from owner complaints in NHTSA records

   “The seat belts on driver's and passenger's sides hang out of the retractor ,causing the belts to get caught in the door, the belts become frayed. The problem has been reported to the dealer. The problem has not been corrected.”

   NHTSA complaint #836251, filed 1999-04

   “Vehicle driver side shoulder belt buckle is inoperative. Buckle will not stay latched. Resutlting in the driver not being restraint in the seat. Dealer contacted. Please provide more details ts”

   NHTSA complaint #8022028, filed 2002-10
4. 4
   Transmission and drivetrain

   Stalling, clutch and shift problems

   • 8 complaints (11%)
   • typically at 5.7 yrs old
   • filed 1995–2004

   Owners describe the engine stalling at speed and restarting after being allowed to cool, with one dealer unable to find the cause, and clutch hydraulic components leaking fluid into the bell housing so the vehicle is hard to shift out of gear. Another report describes a clutch hose that repeatedly pops loose, leaving the clutch inoperable, and one owner says the dealer found nothing wrong. Reported at various mileages with no clear pattern; stalling is described as more likely in very hot weather.

   What to check: Ask about any history of stalling or hard shifting, and check the clutch fluid level and the area around the bell housing for leaks. A test drive that includes shifting through all gears and a hot restart is worthwhile.

   2 excerpts from owner complaints in NHTSA records

   “While driving at any speed vehicle stalled. Consumer tried to restart vehicle and was able to do so. Consumer drove vehicle to the dealer for inspection, and dealer was unable to resolve the problem.”

   NHTSA complaint #10067483, filed 2004-04

   “The hydraulic release bearing clutch leaks fluid into the bell housing, making it hard to shift out of a gear. Took to dealer and was told that nothing was wrong with the truck.”

   NHTSA complaint #822276, filed 1998-04

Buying note. This is an old vehicle with several long-standing recall items, so confirming which recalls (parking brake, fuel tank sending unit, front brake hose) were completed, and inspecting for fuel leaks and brake hose chafing, matters more than mileage. Have the parking brake, belts, and fuel system checked directly rather than relying on service records alone.

Summary written with AI from a sample of 38 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.