Model year record

1991 Jeep Wrangler recalls & problems

The 1991 Jeep Wrangler has 8 safety recalls and 76 owner complaints on file with NHTSA. The most-reported problem area is fuel system, gasoline (18 complaints).

Recalls8safety recalls

Complaints76filed by owners

Crashes · fires4 · 3reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Exterior lightingMar 23, 2006

Exterior lighting

Recall 06E02600061,944 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

EquipmentJun 7, 2004

Equipment

Recall 04E04100080 vehicles

Problem: BESTOP AFTERMARKET REAR SHELL ROOF RACKS,MANUFACTURED BETWEEN APRIL 27 AND MAY 20, 2004, DESIGNED FOR USE WITH THE BESTOP HARDTOP MADE FOR THE 1986-1995 AND 1997-2003 JEEP WRANGLER. THE COCKPIT COVER MAY NOT STAY LATCHED TO THE ROOF RACK BECAUSE THE LATCH BRACKET MISPOSITIONS THE ROTARY LATCH TO THE COCKPIT COVER. AS A RESULT, THE COCKPIT COVER MAY NOT STAY LATCHED TO THE ROOF RACK AND COULD SEPARATE FROM THE ROOF RACK. THIS RECALL ONLY PERTAINS TO AFTERMARKET REAR SHELL ROOF RACKS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON JEEP WRANGLER VEHICLES BY DAIMLERCHRYSLER.
Risk: SHOULD THIS OCCUR, THE COCKPIT COULD CAUSE INJURY BY STRIKING PERSONS OUTSIDE THE VEHICLE OR COULD BECOME A DISTRACTION OR AN OBSTACLE TO OTHER DRIVERS, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: BESTOP WILL NOTIFY ITS CUSTOMERS AND PROVIDE A REPAIR KIT AND INSTALLATION INSTRUCTIONS FREE OF CHARGE. OWNER NOTIFICATION BEGAN JUNE 16, 2004. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BESTOP CUSTOMER SERVICE DEPARTMENT AT (800) 845-3567.

Parking brakeFeb 7, 2002

Conventional

Recall 02V041000316,148 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH MANUAL TRANSMISSIONS, THE PARKING BRAKE CAN SELF-RELEASE WITHOUT WARNING.
Risk: THIS COULD ALLOW THE VEHICLE TO ROLL AWAY, INCREASING THE RISK OF A CRASH.
Fix: DEALERS WILL INSTALL A PARKING BRAKE ASSEMBLY WITH A STRONGER PAWL RETURN SPRING. OWNER NOTIFICATON BEGAN SEPTEMBER 30, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

Service brakes, hydraulicJan 12, 1998

Foundation components › Disc › Rotor

Recall 98V005000293,369 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: PASSENGER AND MULTI-PURPOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, ILLINOIS, INDIANA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, OR WISCONSIN, AND THE DISTRICT OF COLUMBIA. THE FRONT DISC BRAKE ROTORS CAN EXPERIENCE SEVERE CORROSION IF OPERATED FOR AN EXTENSIVE PERIOD IN THE "SALT BELT." IF THE ROTORS ARE NOT REPLACED, THE CORROSION CAN EVENTUALLY COMPROMISE THE STRUCTURAL INTEGRITY OF THE STAMPED STEEL CENTER HUB SECTION OF THE ROTOR.
Risk: THE REDUCED STRENGTH CAN ALLOW THE CAST IRON WEAR SURFACE TO SEPARATE FROM THE HUB, REDUCING THE BRAKE EFFECTIVENESS OF THE VEHICLE.
Fix: DEALERS WILL REPLACE THESE ROTORS WITH ROTORS THAT ARE COATED WITH A CORROSION PROTECTION.

Fuel system, gasolineJun 9, 1994

Delivery › Fuel pump

Recall 94V106000230,000 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: MULTIPURPOSE PASSENGER VEHICLES EQUIPPED WITH PLASTIC FUEL TANKS. THE FUEL TANK SENDING UNIT GASKET CAN CRACK CAUSING FUEL AND FUEL VAPOR LEAKS.
Risk: FUEL AND FUEL VAPOR LEAKED FROM THE FUEL TANK CAN RESULT IN FIRE WHEN EXPOSED TO A SOURCE OF IGNITION.
Fix: REPLACE THE FUEL TANK SENDING UNIT GASKET.

Electrical systemMay 11, 1993

Ignition › Switch

Recall 93V083000100,000 vehicles

Problem: SALT CORROSION PRODUCTS BETWEEN THE STARTER SOLENOID WIRE AND THE ADJACENT BATTERY FEED IN THE BULKHEAD CONNECTOR MAY SHORT THESE CONNECTIONS, CAUSING THE CIRCUIT TO BYPASS THE IGNITION KEY CONTROL OF THE STARTER MOTOR SOLENOID. THE CAR CAN START WITHOUT THE STARTER SEQUENCE BEING INITIATED BY THE IGNITION KEY IN THE IGNITION LOCK.
Risk: THE UNINTENDED START OF A VEHICLE WITH A MANUALTRANSMISSION LEFT IN A DRIVE GEAR CAN RESULT IN A RUNAWAY VEHICLE.
Fix: THE STARTER SOLENOID WIRING WILL BE SEPARATED FROM THE BATTERY FEED WIRE BY RELOCATING IT WITHIN THE BULKHEAD CONNECTOR ON AFFECTED VEHICLES.

Service brakes, hydraulicOct 14, 1992

Foundation components › Hoses, lines/piping, and fittings

Recall 92V148000280,000 vehicles

Problem: ON 1987 THROUGH EARLY 1990 MODELS, BOTH FRONT BRAKE HOSES CAN WEAR DUE TO DIRECT CONTACT WITH THE WHEEL OPENING SPLASH SHIELDS. ON THE LATE 1990 THROUGH 1992 MODELS, PERIODIC RUBBING CONTACT OF THE LEFT FRONT BRAKE HOSE CAN OCCUR DUE TO MOVEMENT OF THE SPLASH SHIELD IN CERTAIN VEHICLE OPERATING CONDITIONS.
Risk: EITHER CONDITION CAN CAUSE LOSS OF FRONT BRAKE SYSTEMFUNCTIONS, RESULTING IN INCREASED STOPPING DISTANCES AND AN INCREASED RISK OFVEHICLE ACCIDENT.
Fix: THE 1987 TO 1990 MODEL VEHICLES WILL HAVE BOTH SPLASH SHIELDS REPLACED AND BOTH FRONT BRAKE HOSES REPLACED AS NECESSARY. ALL AFFECTED LATE 1990 THROUGH 1992 MODEL YEAR VEHICLES WILL HAVE ADDITIONAL FASTENERS INSTALLED TO FURTHER SECURE THE LEFT SIDE SPLASH SHIELD. ALSO, THE LEFT FRONT BRAKE HOSE WILL BE INSPECTED AND REPLACED AS NECESSARY.

EquipmentOct 3, 1990

Other › Labels

Recall 90V1780002,800 vehicles

Problem: CERTIFICATION LABEL DOES NOT CONTAIN REQUIRED TIRE AND WHEEL INFORMATION.
Risk: VEHICLES WOULD NOT COMPLY WITH FMVSS 120.
Fix: INSTALL SUPPLEMENTAL TIRE INFORMATION LABELS ADJACENT TO CERTIFICATION LABELS.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

Wrangler 4WD

17mpg combined

City / highway	16 / 18 mpg
Fuel	Regular Gasoline

2.5 L · 4 cyl · Manual 5-spd · 4-Wheel or All-Wheel Drive · about $3,950/year to fuel

Wrangler 4WD

17mpg combined

City / highway	15 / 20 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Manual 5-spd · 4-Wheel or All-Wheel Drive · about $3,950/year to fuel

Wrangler 4WD

14mpg combined

City / highway	13 / 16 mpg
Fuel	Regular Gasoline

4 L · 6 cyl · Automatic 3-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Typical mileage*
Fuel system, gasolineStorage › Tank assembly; Delivery › Fuel pump	18	0	0	—
Engine and engine coolingEngine; Exhaust system › Emission control › Catalytic convertor	14	0	0	—
Parking brakeConventional	13	4	0	115,000 mi
Seat beltsFront › Retractor; Front › Buckle assembly	11	0	0	—
Power trainAutomatic transmission; Clutch assembly	10	1	0	—
Electrical systemIgnition › Module; Wiring	9	0	3	—
Service brakes, hydraulicFoundation components › Hoses, lines/piping, and fittings; Brake fluid low warning › Lamp	7	0	0	—
EquipmentAppliance › Air conditioner; Electrical › Radio/tape deck/cd etc.	2	0	0	—
SuspensionRear	2	0	0	—
Latches/locks/linkagesHood › Latch; Doors › Latch	2	0	0	—
Fuel system, other	2	0	0	—
TiresTread/belt	2	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Parking brake
The contact owns a 1991 Jeep Wrangler. The contact received notification of NHTSA Campaign Number: 02V041000 (Parking Brake), 94V106000 (Fuel System, Gasoline) however, the part to do the recall repair was not available at the contacts local dealer. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue and directed her to another dealer where the parts were not available. The contact had experienced a failure.Â VIN tool confirms parts available. Failure Mileage was 115,000.
Oct 15, 2023 · 115,000 miles
Tires
I WAS DRIVING ON THE HIGHWAY AT 55 MPH AND MY LEFT REAR TIRE EXPERIENCED A SUDDEN LOSS OF AIR PRESSURE AND THE SIDEWALL BLOW OUT. THERE IS NO VISIBLE HOLES IN TREAD. TREAD RECENTLY PASSED STATE INSPECTION. I HAVE A SPECIAL ORDER TIRE 35X12.5 15LT. THESE ARE BF ALL TERRAN T/A TIRES.
Oct 5, 2016 · 214,000 miles
Fuel/propulsion system
TL* THE CONTACT OWNS A 1991 JEEP WRANGLER. WHILE REFUELING THE VEHICLE, FUEL LEAKED FROM THE BOTTOM OF THE VEHICLE. THE FAILURE RECURRED SEVERAL TIMES. THE FUEL TANK WAS REPLACED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.
May 29, 2015 · 70,000 miles
Fuel system, gasoline
JEEP WRANGLER YJ OVERFILLS THE TANK WHEN PUMPING GAS AND CAUSES FUEL TO SPILL OUT OF THE HOLE AND CAUSES HAZARDOUS CONDITIONS. *TR
Oct 13, 2010
Fuel system, gasoline
GAS TANK DOES NOT REGISTER PROPER AMOUNT. *TR
Mar 27, 2010
Fuel system, gasoline › Fuel injection system › Fuel rail
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. BASED ON MY RESEARCH BY CONTACTING 3 DEALERSHIPS IN THE WASHINGTON, DC AREA, JEEP HAS STOPPED PRODUCING THIS PART AND THERE ARE NO STOCK AFTERMARKETS FUEL RAILS AVAILABLE. I'M LOOKING INTO JUNKYARD PARTS BUT QUESTION WHETHER IF…
Nov 1, 2006 · 106,000 miles
Seat belts › Front › Buckle assembly
DRIVERS FEMALE SEAT BELT END RELEASES ON ITS OWN OR DOES NOT LATCH AT ALL. I STILL HAVE THE OLD PART. *NM
Dec 12, 2005
Fuel system, gasoline › Storage › Tank assembly
DT: 1991 JEEP WRANGLER. THE CONSUMER STATED THAT GAS POURED OUT OF THE PLASTIC TANK. IT CRACKED ON THE RIGHT LOWER CORNER. THE VEHICLE WAS NOT TAKEN TO THE DEALERSHIP. THE CONSUMER DID REPAIRS BY HIMSELF HIMSELF. BUT WHEN HE PUT MORE GAS IN THE VEHICLE IT BEGAN TO LEAK AGAIN. THE MANUFACTURER HAS NOT BEEN NOTIFIED. *AK
Aug 7, 2005

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

FUEL LEAKAGEClosedLed to recall 94V106000
ODI HAS RECEIVED 6 REPORTS ON FUEL LEAKAGE AND 3 REPORTS ON ALLEGED REMEDY FAILURE REPORTS
RQ97016 · opened Oct 27, 1997 · closed Jun 30, 1998
REAR AXLE SHAFT SEPARATIONClosed
THIS INVESTIGATION WAS OPENED TO EXAMINE THE FAILURE MODE AND THE RISK TO MOTOR VEHICLE SAFETY POSED BY ALLEGATIONS OF REAR AXLE SEPARATIONS.THE REAR AXLE SHAFT AND HOUSING DESIGN IS TYPICAL OF THOSE IN WHICH THE WEIGHT OF THE VEHICLE IS CARRIED ON THE AXLE HOUSING.THE LEFT AND RIGHT AXLE SHAFTS, SUPPORTED BY ROLLER BEARINGS, ARE SITUATED INSIDE THE AXLE HOUSING.THE INBOARD SPLINED END OF THE AXLE SHAFT RECEIVES POWER TRANSMITTED FROM THE DIFFERENTIAL ASSEMBLY, PROVIDING TORQUE TO THE REAR WHEELS.THE ALLEGATIONS ARE THAT THE AXLE SHAFT FAILS, RESULTING IN THE SEPARATION OF A WHEEL AND AXLE HUB ASSEMBLY OR THE ENTIRE AXLE SHAFT AND WHEEL ASSEMBLY, DEPENDING ON THE LOCATION OF THE AXLE SHAFT FAILURE.AS IDENTIFIED BY CHRYSLER, THE SUBJECT REAR AXLES ARE DANA 35C AND 35CM MODELS, WHICH HAVE BEEN USED ON THE SUBJECT VEHICLES SINCE THE 1990 MODEL YEAR.A SAFETY DEFECT TREND WITH RESPECT TO THE…
PE95049 · opened Aug 17, 1995 · closed Jan 26, 1996
SENDING UNIT GASKET FAILSClosedLed to recall 94V106000
There is no summary currently available
EA93031 · opened Dec 15, 1993 · closed Jun 17, 1994
DRIVESHAFT/UNIV.JOINT FAILClosed
There is no summary currently available
EA93025 · opened Oct 29, 1993 · closed Nov 25, 1994