1991 Dodge Caravan Recalls, Problems & Maintenance

The 1991 Dodge Caravan has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “ABS warning light and loss of braking.” Dodge uses Stellantis' Oil Change Indicator — it watches engine load and duty cycle and messages when to change oil, capped at 10,000 miles or 12 months. Know your engine: the 3.6L Pentastar V6 goes 100,000 miles on plugs, while HEMI V8s carry sixteen plugs (two per cylinder) on a roughly 30,000-mile interval — that's a real cost difference at the service counter. HEMI models with MDS cylinder deactivation are especially sensitive to overdue oil.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 1991 Dodge Caravan.

Reported to NHTSA

ABS warning light and loss of braking

SERVICE BRAKES, HYDRAULIC

44 NHTSA complaints · 1998-12 → 2014-08

“ABS BRAKING LIGHT APPEARS ON DASHBOARD AND PEDAL IS HARD AND GOES ALL THE WAY DOWN TO THE FLOOR. DEALERSHIP IS AWARE OF PROBLEM.*AK CONSUMER STATES THAT ABS AND BRAKE LIGHTS COMES ON AND PUMP WAS RUNNING EVERY PEDAL APPLICATION DUE TO WEAK ACCUMULATOR. ALSO, MODULATOR FAULT WAS C”
— Owner report, NHTSA ODI #8016644
“THE ABS LIGHT ILLUMINATED, AND THE BRAKE PEDAL TRAVELED TO THE FLOOR WHEN APPLIED.*JB”
— Owner report, NHTSA ODI #10007208
“WHILE TRAVELING AT 65 MPH THE CONSUMER TRIED TO SLOW DOWN BUT THE BRAKES WERE NOT WORKING, CONSUMER CONTACTED DEALER AND THE DEALER NOTED THAT THERE WAS A PROBLEM WITH THE ABS, BUT IT SHOULD ONLY HAPPEN ON ONE SIDE OF THE ABS, THIS WAS THE SECOND TIME THIS PROBLEM HAS HAPPENED. *”
— Owner report, NHTSA ODI #8002430

Read all complaints on NHTSA →

Sliding door and liftgate detachment or failure

STRUCTURE

15 NHTSA complaints · 1998-12 → 2003-08

“PASSENGER'S SIDE SLIDING DOOR HAS COMPLETELY FALLEN OFF THE TRACKS,CAUSE UNKNOWN. *AK”
— Owner report, NHTSA ODI #832435
“RECALL 99V213000/ MANUFACTURER'S RECALL 730; STRUTS WHICH SUPPORT THE LIFTGATE BROKE, ALLOWING THE LIFTGATE TO FALL SUDDENLY. CONSUMER HAS CONTACTED THE DEALER. PLEASE PROVIDE ANY FURTHER DETAILS. *AK”
— Owner report, NHTSA ODI #856590
“WHILE DRIVING HEARD A NOISE. AFTER PARKING VEHICLE THEY NOTICED THAT REAR HATCH DOOR WAS DETACHED FROM VAN BY A INCH OR TWO. DRIVER WAS UNABLE TO OPEN DOOR COMPLETELY. CONSUMER WAS AFRAID THAT DOOR WILL FALL OFF COMPLETELY WHILE DRIVING.*AK”
— Owner report, NHTSA ODI #8009281

Read all complaints on NHTSA →

Windshield and rear wiper failure

VISIBILITY

7 NHTSA complaints · 2000-03 → 2002-06

“WHILE DRIVING HOME IN THE RAIN WINDSHIELD WIPERS COMPLETELY STOPPED WORKING. CONSUMER COULD HEAR MOTOR RUNNING, BUT WIPERS WERE NOT ON.*AK”
— Owner report, NHTSA ODI #864428
“REAR WIPER STUCK IN UP POSITION, TOOK TO DEALER WHO INFORMED HER ONLY FRONT WIPER ON RECALL, SAID WIPER MOTOR NEEDS TO BE REPLACED.*AK”
— Owner report, NHTSA ODI #874608

Read all complaints on NHTSA →

ABS recall repair cost and reimbursement

SERVICE BRAKES, HYDRAULIC

11 NHTSA complaints · 1999-02 → 2007-02

“DT*: THE CONTACT STATED RECALL # 96V099000 FOR THE SERVICE BRAKES: HYDRAULIC: ANTI-LOCK WAS RECEIVED. WHEN THE SERVICE DEALER WAS CALLED TO SCHEDULE THE RECALL REPAIR, THE SERVICE DEALER INFORMED THE CONTACT, THERE WOULD BE CHARGES FOR REPLACING THE ACCUMULATOR PLUS LABOR COSTS”
— Owner report, NHTSA ODI #10173961
“DT*: THE CONTACT STATED RECALL WORK WAS PERFORMED ON THE VEHICLE PRIOR TO THE CONTACT BEING AWARE OF THE RECALL. THE MANUFACTURER WAS CONTACTED ABOUT REIMBURSEMENT WHICH THEY DENIED BECAUSE THE RECALL WORK WAS NOT PERFORMED AT AN AUTHORIZED DEALERSHIP. THE NHTSA RECALL # 96V09900”
— Owner report, NHTSA ODI #10153152
“RECALL 96V099000 CONCERNING ABS BRAKE FAILURE. VEHICLE WAS REPAIRED UNDER THE RECALL. 30,000 MILES LATER BRAKES FAILED AGAIN. DEALER DID A DIAGNOSTIC TEST, AND DETERMINED THAT THE PARTS THAT WERE REPAIRED UNDER THE RECALL FAILED, CAUSING THE VEHICLE TO LOSE BRAKE POWER. DEALER WO”
— Owner report, NHTSA ODI #10059172

Read all complaints on NHTSA →

Automatic transmission failure and replacement

POWER TRAIN

14 NHTSA complaints · 1998-11 → 2005-03

“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. *AK”
— Owner report, NHTSA ODI #10115812
“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. *AK”
— Owner report, NHTSA ODI #864318
“THIS IS THE SECOND TIME THA TTRANSMISSION FAILED ON THIS 91 DODGE CARAVAN. THE FIRST FAILURE OCCURRED AT 81000 MILES IN FEBRUARY '99 WHICH WAS THE ORIGINAL TRANSMISSION WHEN THE CAR WAS PURCHASED NEW. THE TRANSMISSION WAS REPAIRED AT A DODGE DEALERSHIP AND LASTED ONLY 28000 MILES”
— Owner report, NHTSA ODI #735644

Read all complaints on NHTSA →

Fuel rail and fuel line leaks

FUEL SYSTEM, GASOLINE

18 NHTSA complaints · 1998-12 → 2005-11

“WHEN STARTING VEHICLE THE GAS FUMES WERE SO STRONG THAT VAN WAS TURNED OFF AND NOT DRIVEN. HUSBAND STARTED VAN ONCE AGAIN LATER, CHECKED UNDER HOOD AND FUEL WAS SHOOTING OUT ALL OVER ENGINE. FUEL RAIL WAS FOUND TO BE SPLIT IN ENGINE COMPARTMENT. WHEN VEHICLE WAS TOWED TO A MECHAN”
— Owner report, NHTSA ODI #841564
“THERE WAS A FIRE IN ENGINE COMPARTMENT DUE TO A FUEL RAIL LEAK. DEALER HAS NOT BEEN CONTACTED.*AK SUBSEQUENT INSPECTION SHOWED LEAKS AT BOTH JOINTS OF FUEL RAIL. THE MANUFACTURER OF THE VEHICLE CLAIMS THAT IT WAS NOT CAUSED BY MANUFACTURING ERROR, BUT THE CONSUMER CITS NTHSA WEBS”
— Owner report, NHTSA ODI #875227
“WHILE DRIVING PUT HEAT ON AND STARTED SMELLING GAS FUMES INSIDE OF VEHICLE. TOOK TO DEALER. MECHANIC COULD NOT LOCATE OR SMELL FUMES. NEXT DAY, TURNED ON HEAT TO WARM UP, WENT INSIDE, AND THEN CAME 15 MINUTES LATER AND VEHICLE WAS IN FLAMES. FIRE DEPARTMENT ARRIVED AND PUT FLAMES”
— Owner report, NHTSA ODI #878531

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (Oil Change Indicator)

Every 10,000 mi

Change when the indicator says so — never beyond 10,000 miles or 12 months. Pentastar 3.6L: 0W-20. HEMI 5.7L: 5W-20 (0W-40 for 6.4L SRT). MDS-equipped HEMIs punish stretched oil intervals with lifter and cam wear.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 8,000 mi

Rotate every 8,000 miles. Charger/Challenger R/T and Scat Pack: staggered-width setups can't rotate front-to-rear — budget rear tires accordingly.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect pads and rotors at every oil change. Heavy Durangos used for towing and hard-driven Chargers both run through rear pads faster than the front-pad-first rule of thumb suggests.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Spark Plugs

Every 30,000 mi

HEMI 5.7L: sixteen plugs roughly every 30,000 miles — check your year's manual. Pentastar 3.6L (Charger/Challenger V6, Durango V6, Journey, Grand Caravan): 100,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Automatic Transmission Fluid

Every 60,000 mi

Grand Caravan/Journey (62TE): ATF+4 service every 60,000 miles in family duty. Charger/Challenger/Durango with the TorqueFlite 8-speed: no published normal interval, but specialists recommend service around 60,000-100,000 miles — sooner with towing.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Rear Differential Fluid

Every 60,000 mi

RWD Charger/Challenger and AWD Durango: replace rear diff fluid around 60,000 miles, sooner with towing or drag-strip duty. Limited-slip units need the friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Engine Air Filter

Every 30,000 mi

Replace every 30,000 miles. HEMIs pull serious airflow — a clogged filter costs measurable power before it throws a code.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Serpentine Belt

Every 60,000 mi

Inspect from 60,000 miles, replace on cracking or glazing. On the HEMI, a shredded belt can take the cooling drive with it mid-drive.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace every 20,000 miles where equipped (behind the glovebox on most models). Some earlier Journeys and Avengers shipped without one — check before buying a filter.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Coolant Replacement (OAT)

Every 100,000 mi

Stellantis OAT coolant is scheduled for 10 years / 150,000 miles; shops commonly refresh by 100,000. OAT-compatible coolant only — mixing chemistries gels the system.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Battery Test & Service

Every 25,000 mi

Test annually after year 3. Big-audio Chargers and tow-package Durangos lean on the battery hard; weak batteries surface as gremlins in the electronics before they fail to crank.

Estimated cost — typical U.S. ranges

Dealer

~$225–$390

Shop

~$160–$280

DIY

~$130–$250

Most auto-parts stores test and install batteries free with purchase. Skip the dealer markup.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

247 crashes 1990–2024

How the 247 occupant deaths break down

143

driver deaths

104

passenger deaths

247

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 1991 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

43

complaints mentioning a crash

13

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 1991 Dodge Caravan reflects Dodge's published service intervals and the Oil Change Indicator System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.