Head gasket and cylinder head failure
ENGINE AND ENGINE COOLING
7 NHTSA complaints · 1996-12 → 2001-10
“ENGINE HEAD FAILED 4TIMES”
“ENGINE GASKET KEEPS BLOWING AND WARPED THE ENGINE HEAD”
1991 Dodge Spirit Recalls, Problems & Maintenance
The 1991 Dodge Spirit has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Head gasket and cylinder head failure.” 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.
Save this car as:
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 Spirit.
Reported to NHTSA
Rear trailing arm, sway bar and axle breakage
SUSPENSION
8 NHTSA complaints · 1996-10 → 2003-01
“REAR TRAILING SUSPENSION ARM BROKE AT WELD”
“VEHICLE HAS A BROKEN TRAILING ARM ON THE REAR SUSPENSION, CAUSING A RATTLING NOISE”
“SWAY BAR/TRAILING ARM CRACKED”
Timing belt failure
ENGINE AND ENGINE COOLING
10 NHTSA complaints · 1995-04 → 1999-11
“WHILE TRAVELING AT APPROXIMATELY 55 MPH, THE TIMING BELT FAILED CAUSING THE VEHICLE TO LOSS ALL POWER WHICH COULD HAVE RESULTED IN INJURY”
“TIMING BELT BREAKS WHEN OPERATING AT 55-60 MPH IN 5TH GEAR WITH THE CRUISE CONTROL ON, ON 7 OCCASIONS EXPERIENCED FAILURE”
“AT 19,000 MILES THE TIMING BELT HAS GONE OUT WITHOUT WARNING”
Sudden acceleration at idle or low speed
VEHICLE SPEED CONTROL
7 NHTSA complaints · 1995-01 → 2001-10
“VEHICLE SUDDENLY ACCELERATED WHENEVER IT WAS AT A STOP OR SLOWING DOWN TO A STOP”
“CONSUMER EXPERIENCED SUDDEN ACCELERATION WHEN GOING AT SLOW SPEED, OFTEN WHEN BRAKES WERE APPLIED”
“VEHICLE WILL ACCELERATE SUDDENLY DURING STOPS OR WHEN IDLING; EXCESSIVE BREAKING IS REQUIRED TO STOP VEHICLE FROM ACCELERATING”
Transmission and transaxle failure
POWER TRAIN
9 NHTSA complaints · 1995-04 → 2000-05
“THE VEHICLE STALLED COMPLETELY OUT WHILE DRIVING DUE TO TRANSMISSION SLIPPING”
“CONSUMER WAS DRIVING AND THE TRANSMISSION LOCKED UP PRIOR TO DOWNSHIFTING”
“AUTO-TRAN: SNAP RINGS BROKE; TRANSMISSION JUMPS OUT OF GEAR; DOES NOT SHIFT AS INTENDED; SPEED 55 MPH; REPLACED; PROBLEM HAS REOCCURRED”
Unintended or injurious air bag deployment
AIR BAGS
7 NHTSA complaints · 1995-05 → 1999-10
“VEHICLES DRIVER SIDE AIRBAG DEPLOYED WHILE DRIVING FOR NO REASON”
“VIOLENT DEPLOYMENT OF AIRBAG, CAUSING BURNS TO DRIVER'S JAW/CHEST”
“FALSE DEPLOYMENT OF AIR BAG”
Steering column wiring overheating and fire
ELECTRICAL SYSTEM
6 NHTSA complaints · 1996-08 → 2000-12
“THE WIRING IN THE STEERING COLUMN STARTED A FIRE AND BURNED THROUGH THE PLASTIC THAT COVERS THE STEERING COLUMN”
“SMOKING STEERING COLUMN DUE TO FAILURE OF THE IGNITION SWITCH”
“VEHICLE'S IGNITION SYSTEM ELECTRCAL WIRING SHORTED AND BURNED UP”
Brake pedal and rotor failure
SERVICE BRAKES, HYDRAULIC
6 NHTSA complaints · 1995-02 → 2001-10
“BRAKE PEDAL HITS BOTTOM DURING HEAVY BRAKING/PANIC STOPPING; NO WARNING; EXTENDED STOPPING; HIGH SPEED ON TURNPIKE, COULD HAVE CAUSED ACCIDENT”
“VEHICLES BRAKING SYSTEM, W WHEEL DISC BRAKES HAVE INTERMITTENTLY FAILED, ALSO SOFT PEDAL AND PEDAL GOES ALL THE WAY TO THE FLOOR”
“ROTORS OVERHEATED, CAUSING ROTORS TO WARP/BRAKE FAILURE”
Issues on other model years
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.
Essential maintenance
Critical for safety and preventing major damage
Engine Oil & Filter (Oil Change Indicator)
Every 10,000 miChange 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 miRotate 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 miInspect 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 miHEMI 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 miGrand 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 miRWD 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 miReplace 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 miInspect 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 miReplace 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 miStellantis 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 miTest 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.
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 Spirit 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.