The 1991 Toyota 4Runner has no open NHTSA recalls. Owners report 4 recurring issue clusters, led by “Cylinder head gasket failure and leaks.” Toyota's owner's manual splits service into Schedule 1 (severe) and Schedule 2 (normal). Most US drivers fall under Schedule 1 because it covers short trips, extreme temperatures, dusty roads, or heavy idling. The intervals below reflect Schedule 1 — the schedule Toyota recommends for typical real-world use.
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.
What drivers and federal regulators have officially reported about the 1991 Toyota 4Runner.
ENGINE AND ENGINE COOLING
15 NHTSA complaints · 1995-02 → 2007-01
“BLOWN HEAD GASKET, 1991 TOYOTA V6 4RUNNER, RECALLED IN 1998 FOR THE PROBLEM, CORRECTED AND GASKET FAILED AGAIN IN 2007”
“WHILE DRIVING, SMELLED COOLANT, VEHICLE WAS SHAKING, CAUSED BY HEAD GASKET BLOWING OUT”
“THERE HAD BEEN A MANUFACTURER'S RECALL OF HEAD GASKETS”
TIRES
4 NHTSA complaints · 2000-08 → 2005-06
“CONSUMER WAS TRAVELING 65MPH ON THE HIGHWAY AND RIGHT REAR TIRE EXPLODED”
“HE STATES THAT HE HAD TREAD SEPARATION ON BRIDGESTONE TIRES”
SERVICE BRAKES, HYDRAULIC
4 NHTSA complaints · 1995-01 → 2005-10
“CORROSION ON THE BREAK LINES FROM POOR DESIGN IN ALLOWING SAND AND DIRT TO ACCUMULATE AND CAUSE THE LINE TO RUST THROUGH AND CREATE A BREAK FAILURE”
“BRAKE ROTORS FAILED, CAUSING SEVERE VIBRATION WHEN APPLYING BRAKES”
STEERING
5 NHTSA complaints · 1995-12 → 2008-01
“MY DAUGHTER WITH TWO GRANDDAUGHTERS WERE DRIVING IN A 91 TOYOTA 4 RUNNER ON A WELL MAINTAINED LOG ROAD WHEN THEY LOST STEERING AND WENT OVER A 30 FT CLIFF”
“1991 TOYOTA 4RUNNER STEERING FAILED WHEN TURNING WHEEL”
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.
Critical for safety and preventing major damage
Replace 0W-20 full-synthetic oil and filter every 5,000 miles under Schedule 1, or 10,000 miles under Schedule 2. Toyota covers the first 2 oil changes through ToyotaCare.
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.
Rotate tires every 5,000 miles. Toyota recommends rotation at every oil change to maximize tire life on FWD and AWD models.
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 brake pads, rotors, and parking brake every 5,000 miles. Toyota recommends measuring pad thickness at each service.
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 DOT 3 brake fluid every 30,000 miles or 36 months. Critical for the integrity of the ABS, VSC, and brake assist systems.
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
Replace the engine air filter every 30,000 miles. Earlier under Schedule 1 if driven on unpaved roads.
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.
Toyota labels ATF as 'lifetime fill' on most automatics, but recommends inspection and replacement every 60,000 miles under severe service. Use Toyota WS or Type-IV — no substitutes.
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.
Toyota iridium-tipped spark plugs are rated for 120,000 miles. Earlier replacement reduces fuel economy and can cause misfires on direct-injection engines.
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.
Toyota SLLC (pink): first change at 100,000 miles, then every 50,000 miles. Do not substitute green or orange coolant — it will damage the cooling system seals.
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.
Extends the life of your vehicle and improves comfort
Replace the cabin air filter every 30,000 miles, sooner in dusty climates. Located behind the glove box on most Toyota and Lexus models.
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.
Inspect the serpentine belt and tensioner every 60,000 miles. Toyota uses long-life EPDM belts that rarely fail before 100,000 miles.
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.
Toyota's 2AR-FE, 2GR-FKS, A25A-FKS, and most Toyota engines built since 2010 use a timing chain rated for the life of the engine. No scheduled replacement.
Estimated cost — typical U.S. ranges
Dealer
~$85
Shop
~$60
DIY
Pro only
Timing chains are normally lifetime. Listen for rattle on cold start — that's the actionable signal. Replacement is major work, quote separately.
Occupant deaths in fatal crashes (FARS)
168 crashes 1990–2024
How the 168 occupant deaths break down
109
driver deaths
59
passenger deaths
168
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.
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.
3
complaints mentioning a crash
0
complaints mentioning a fire
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 Toyota 4Runner reflects Toyota's published service intervals and the Maintenance Required Light 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.