VehicleVerdict

1991 Chevrolet Suburban problems

Verdict · NHTSA data

A typical year for this model

The 1991 Chevrolet Suburban sits mid-pack among Suburban years: 65 NHTSA complaints against a model median of roughly 148, with 4 recalls and one closed investigation.

No single system dominates the record — complaints spread across brakes (15), seats (13), and transmission (11), which usually points to general build quality rather than one defect.

65

NHTSA complaints

4

Recalls

1

Investigations

6

Crash-involved

7

Fires reported

5

Injuries

0

Deaths

—

NCAP overall

How does 1991 compare to other Suburban years?

Suburban NHTSA complaints by model year, 1991 highlighted1,038 complaints1977: 3 complaints1978: 3 complaints1979: 1 complaints1981: 1 complaints1982: 1 complaints1983: 4 complaints1984: 6 complaints1985: 12 complaints1986: 7 complaints1987: 21 complaints1988: 35 complaints1989: 68 complaints1990: 67 complaints1991: 65 complaints1992: 226 complaints1993: 616 complaints1994: 1,038 complaints1995: 587 complaints1996: 531 complaints1997: 556 complaints1998: 299 complaints1999: 861 complaints2000: 382 complaints2001: 543 complaints2002: 352 complaints2003: 361 complaints2004: 265 complaints2005: 161 complaints2006: 33 complaints2007: 358 complaints2008: 276 complaints2009: 133 complaints2010: 161 complaints2011: 193 complaints2012: 139 complaints2013: 170 complaints2014: 77 complaints2015: 588 complaints2016: 297 complaints2017: 184 complaints2018: 111 complaints2019: 92 complaints2020: 60 complaints2021: 241 complaints2022: 149 complaints2023: 140 complaints2024: 50 complaints
Suburban NHTSA complaints by model year, 1991 highlighted. Red bars are years to avoid.

See all Suburban years to avoid →

What are the most common 1991 Chevrolet Suburban problems?

ComponentComplaintsShare
Brakes1523%
Seats1320%
Transmission1117%
Tires & Wheels914%
Engine58%
Seat Belts46%
Electrical System23%
Other23%
Steering23%
Body & Structure12%
Fuel System12%

Does the 1991 Chevrolet Suburban have recalls?

4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E043000Fuel SystemMay 19, 2006 · 88,303 units

Defect

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

96V226000SeatsNovember 4, 1996 · 32,596 units

Defect

THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL VETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEADS TO JOINT LOOSENESS, CAUSING BOLT FATIGUE AND EVENTUAL BOLT FAILURE.

Consequence

IF BOLT FAILURE OCCURS TO THE DRIVER'S SEAT, IT WOULD ALLOW THE SEAT BACK TO SUDDENLY RECLINE, AND COULD RESULT IN LOSS OF VEHICLE CONTROL AND A VEHICLE CRASH WITHOUT PRIOR WARNING.

Remedy

DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT FRAME "SOFT" JOINT AND REPLACE THE RECLINER BOLTS.

93V119000BrakesAugust 2, 1993 · 341,364 units

Defect

SEVERE CORROSION DUE TO ROAD SALT AT THE JOINT OF THE STAMPED STEEL CENTER SECTION AND THE CAST OUTER SECTION CAN CAUSE THE SECTIONS TO SEPARATE.

Consequence

SEPARATION OF THE ROTOR SECTIONS CAN CAUSE LOSS OFBRAKING ABILITY IN THE AFFECTED WHEEL. THIS COULD RESULT IN INCREASED STOPPINGDISTANCE AND/OR LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

Remedy

REPLACE THE FRONT BRAKE ROTORS WITH NEW ROTORS WITH A CORROSION PROTECTION COATING. HOWEVER, IF REPLACEMENT OF BRAKE LININGS ARE NECESSARY, IT WILL BE DONE AT OWNER'S EXPENSE SINCE BRAKE LININGS ARE NORMAL MAINTENANCE ITEMS.

93V016000TransmissionFebruary 1, 1993 · 1,702,880 units

Defect

UNANTICIPATED HEAT IN THE TRANSMISSION CAN FORCE THE TRANSMISSION FLUID OUT OF THE VENT TUBE.

Consequence

THE VENTED TRANSMISSION FLUID CAN CATCH FIRE IF EXPOSEDTO A SOURCE OF IGNITION.

Remedy

INSTALL A LONGER TRANSMISSION VENT HOSE ROUTED TO THE LEFT SIDE OF THE ENGINE COMPARTMENT OF THE VEHICLE.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“OWNER INVOLVED IN TWO ACCIDENTS DUE TO BRAKES LOCKING UP/FAILING TO STOP THE TRUCK. TRUCK IS EQUIPPED W/ABS BRAKES. ALSO REPLACED FRONT BRAKE CALIPERS/PADS/ROTORS AND MASTER CYLINDER. *AK”

Complaint filed with NHTSA · Brakes · January 1, 1995 · crash

“ONGOING PROBLEM WITH THE FOLLOWING: 1. CRACKS DEVELOPING ON BOTH SIDES OF VEHICLE ROOF, CAN BE A POTENTIAL DANGER IN A ROLL OVER ACCIDENT; 2. BRAKES CAUSE ERRATIC OPERATION WHENEVER BRAKES ARE APPLIED, AND CAUSES VEHICLE TO WANDER AROSS THE ROAD, WHICH COULD LEAD TO A POTENTIAL ACCIDENT; AND 3.…”

Complaint filed with NHTSA · Seats · February 15, 1991

“GM WAS AWARE OF THE IMPROPER COMPONENTS INSTALLED IN THIS PARTICULAR TRANSMISSION BUT FAILED TO RECALL CAR AND CORRECT DEFECT.”

Complaint filed with NHTSA · Transmission · crash

“BRIDGESTONE LT 23585R16 DOTEP9JHND205 WHILE DRIVING AT NORMAL SPEEDS THE LEFT REAR TIRE SEPERATED AND DEFLATED, WHICH RESULTED IN A VEHICLE CRASH. PLEASE PROVIDE ANY FURTHER INFORMATION. MR”

Complaint filed with NHTSA · Tires & Wheels · October 1, 2002 · crash

“WHILE DRIVING AT APPROXIMATELY 65 MPH, NOTICED FLAMES COMING OUT OF VEHICLE. UPON OPENING HOOD, NOTICED THAT ALTERNATOR OVERHEATED, RESULTING IN A VEHICLE FIRE. ALSO SERPENTINE BELT OVERHEATED/BURNED. *AK”

Complaint filed with NHTSA · Engine · August 3, 1997 · fire

1991 Chevrolet Suburban — common questions

Is the 1991 Chevrolet Suburban reliable?

Its record is better than the model's norm: 65 NHTSA complaints, below the typical Suburban year, with 4 recalls and no open investigations.

What are the most common 1991 Suburban problems?

According to NHTSA complaint data, the leading problem areas are brakes (15 complaints), seats (13 complaints), transmission (11 complaints).

Does the 1991 Chevrolet Suburban have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 1991 Chevrolet Suburban. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1991 Chevrolet Suburban under NHTSA investigation?

NHTSA opened one investigation into this model year; all are now closed.

Which Chevrolet Suburban years should you avoid?

Based on complaint rates and open investigations, the Suburban years to avoid are 1994, 1999, 1993, 2015, 1995, 1997, 2001, 1996, 2000, 2003, 2007, 2002, 1998, 2016, 2008, 2004, 2021, 1992, 2011, 2013, 2010, 2022, 2023, 2012, 2009, 2014, 2024. The cleanest record among Suburban years belongs to 1982.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.