The 1991 Plymouth Sundance carries 4 open NHTSA recalls — most recently covering recliner and steering wheel/handle bar. Owners report 4 recurring issue clusters, led by “Seat back bolt failure and seat adjustment.” Plymouth ended in 2001, and everything with the badge is a Chrysler or Dodge underneath. The Voyager is a Caravan, the Neon is a Dodge Neon, the Laser is an Eagle Talon and a Mitsubishi Eclipse. Parts are shared and easy to find. Two things decide whether one of these lasts. First, the four-speed automatic in the minivans and Neons requires Chrysler ATF+4 fluid specifically. Generic Dexron will make it shudder and then fail, and this is the most common way these transmissions die. Second, several engines here use a rubber timing belt, including the 3.0 liter Mitsubishi V6 in the minivans, the 2.0 in the Neon, and the turbocharged four in the Laser. On the Laser's engine a snapped belt bends valves. If you cannot document the last belt, treat it as due.
SEATS:FRONT ASSEMBLY:RECLINER
Campaign #99V212000 · Jun 8, 1999
Issue: VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER SEAT CAN FAIL AND SEPARATE.
Risk: IF THE BOLT FAILS WHILE THE VEHICLE IS BEING DRIVEN, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, INCREASING THE RISK OF A VEHICLE CRASH.
Fix: DEALERS WILL REPLACE THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT WITH A HIGHER STRENGTH BOLT THAT INCLUDES A SELF LOCKING NYLON PATCH.
STEERING: STEERING WHEEL/HANDLE BAR
Campaign #96V229000 · Nov 18, 1996
Issue: THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.
Risk: IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTROL CAN OCCUR INCREASING THE RISK OF AN ACCIDENT.
Fix: DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY STEERING WHEELS SHOWING CRACKS WILL BE REPLACED. ALL OTHER VEHICLES WILL HAVE A REINFORCEMENT PLATE INSTALLED TO PREVENT STEERING WHEEL SEPARATION IN THE EVENT CRACKING OCCURS.
SEATS:FRONT ASSEMBLY:RECLINER
Campaign #97V078000 · Oct 5, 1997
Issue: THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT CAN FAIL AND SEPARATE.
Risk: IF THE BOLT FAILS WHILE THE VEHICLE IS BEING DRIVEN, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, INCREASING THE RISK OF A VEHICLE CRASH.
Fix: DEALERS WILL REPLACE THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT WITH A HIGHER STRENGTH BOLT THAT INCLUDES A SELF LOCKING NYLON PATCH.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
Campaign #90V162000 · Apr 9, 1990
Issue: FRONT DISC BRAKE CALIPER GUIDE PIN BOLTS MAY NOT HAVE BEEN ADEQUATELY TORQUED AND COULD LOOSEN.
Risk: THIS COULD CAUSE REDUCED BRAKING EFFECTIVENESS AND COULDRESULT IN AN ACCIDENT.
Fix: PROPERLY TORQUE FRONT BRAKE CALIPER GUIDE PIN BOLTS TO 250 POUNDS.
What drivers and federal regulators have officially reported about the 1991 Plymouth Sundance.
SEATS
7 NHTSA complaints · 1995-01 → 1997-11
“WHILE DRIVING ABOUT 15 MPH THE DRIVER'S SIDE SEAT BACK COLLASPED BACKWARDS. THE BOLTS COMPLETELY SHEARED OFF”
“DRIVERS SEAT BACK BOLT FAILED WHILE DRIVING, CAUSING SEAT BACK TO FALL BACKWARDS”
“DEALERSHIP HAD TO ORDER NEW SEAT BECAUSE BEFORE RECALL NOTICE BOLT HAD ALREADY BROKEN”
SUSPENSION
4 NHTSA complaints · 1996-11 → 1998-08
“TORSION BAR WELDING BROKE IN REAR AXLE CAUSING NOISE AND BAD PERFORMANCE”
“THE SUSPENSION BAR THAT RUNS FROM RIGHT TO LEFT BRAKE CRACKED, CAUSING GRINDING”
“CONSUMER STATES THAT THE REAR AXLE IS CRACKED”
POWER TRAIN
2 NHTSA complaints · 1995-05 → 1995-08
“AUTO-TRAN: CAN REMOVE KEYS FROM IGNITION WITHOUT GEAR IN PARK POSITION; CAN SHIFT GEARS WITHOUT IGNITION SWITCH TURNED; ROLLED ONTO STREET; HIT PARKED CAR”
“AUTOMATIC TRANSMISSION GEAR SELECTOR WHILE SHIFT GEARS WITHOUT PRESSING THE BUTTON”
STRUCTURE
5 NHTSA complaints · 1996-10 → 1999-08
“HATCHBACK STRUT RODS FAILED CAUSING INJURY TO CONSUMER'S SPINAL COLUMN”
“REAR HATCHBACK LIFT GATE FALLS DOWN DUE TO SUPPORT RODS”
“WHEN THE WEATHER IS COLD THE LIFTBACK DOES NOT STAY IN OPEN POSITION/NEEDS TO BE PROPPED WITH A STICK OOR BOX”
Note: NHTSA also opened 5 defect investigation(s) on this vehicle that closed without action.
Issues on other model years
Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 1, 2026.
We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.
Critical for safety and preventing major damage
Chrysler specified 3,000 miles under the severe schedule, which is where an engine of this age belongs. Change at least once a year even if the car barely moves. Nothing in this lineup has an oil life monitor, so the interval is on you.
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.
Use Chrysler ATF+4 and nothing else. The 41TE transaxle, still often called the Ultradrive, is sensitive to fluid friction characteristics in a way most automatics are not. Drain and fill every 30,000 miles. If a shop offers to top it off with universal fluid, decline.
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.
Applies to the 3.0 V6 in the Voyager and Acclaim, the 2.0 in the Neon, and the turbo four in the Laser and Colt. Replace every 90,000 miles or 7 years, whichever comes first, and change the water pump and tensioner at the same time. The Laser's 4G63 is an interference engine, so a failed belt is engine damage rather than a tow. The 3.3 and 3.8 V6 use a chain instead and are not on this schedule.
Estimated cost — typical U.S. ranges
Dealer
~$935–$1175
Shop
~$655–$825
DIY
Pro only
On interference engines, a snapped belt destroys valves. Worth doing on schedule. Bundle water pump + tensioner — labor is already there.
Rotate every 7,500 miles. Check the DOT date code on the sidewall. On a car this old, tires almost always age out before the tread runs out.
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.
Inspect pads, rotors, hoses, and hard lines at every service. Rear drums on the Neon, Sundance, and Acclaim seize on cars that sit, and rusted steel lines are a real concern anywhere road salt is used.
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.
Replace every 2 years. On a twenty-five-year-old car this is what keeps the master cylinder and the ABS unit from becoming the repair bill.
Estimated cost — typical U.S. ranges
Dealer
~$180–$200
Shop
~$125–$140
DIY
~$10–$25
DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.
Keeps your vehicle running smoothly and efficiently
Copper plugs run 30,000 miles, platinum closer to 100,000. Replace the plug wires at the same time on anything with a distributorless coil pack. After this many years the wires break down before the plugs do.
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.
Replace every 30,000 miles. Simple on every model in the lineup.
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.
This is the accessory belt, not the timing belt. Replace the belt and tensioner together once either is cracked, glazed, or noisy.
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.
Extends the life of your vehicle and improves comfort
Every 3 to 5 years. Most of this era uses conventional green coolant rather than a long-life formula, so do not stretch it on the assumption that modern intervals apply. The 2.0 Neon engine has a known head gasket history, and clean coolant with a correct pressure cap is the cheapest defense.
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.
Test the battery and alternator once a year. Corroded ground straps are common at this age and produce electrical faults that look far worse than they are.
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 Plymouth Sundance reflects Plymouth's published service intervals. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.