1991 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated August 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 GMC Safari has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues with published estimates, repair costs range from $100 to $800. DIY maintenance guides at au7o.io.
FUEL SYSTEM, GASOLINE
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.
EXTERIOR LIGHTING
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.
SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT
CERTAIN MINIVANS HAVE AN INTERFERENCE CONDITION BETWEEN THE LOWER BALL JOINT RUBBER BOOT AND THE STEERING KNUCKLE (BOTH LEFT/RIGHT SIDES), WHICH COULD RESULT IN CUTTING OF THE BOOT THAT IS INTENDED TO SEAL THE BALL JOINT. IF THE LOWER BALL JOINT BOOT WERE CUT, CONTAMINATION FROM THE ROAD (SALT, DIRT, WATER, ETC.) COULD ENTER THE BALL SOCKET AREA OF THE BALL JOINT CAUSING THE JOINT TO WEAR OUT TOO QUICKLY.
EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
ON CERTAIN MINIVANS, THE MULTIFUNCTION SWITCH MAY DEVELOP AN OPEN CIRCUIT CONDITION IN THE STOP LAMP OR HAZARD LAMP CIRCUIT THAT RESULTS IN THE STOP LAMPS AND HAZARD LAMPS BEING INOPERATIVE.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 GMC Safari has 2 documented issues. The most frequently reported are: In-Tank Fuel Pump Failure, Rear Dutch Door Latch and Hinge Failure. None are rated critical, but regular maintenance is recommended.
The 1991 GMC Safari has 2 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. No issues are rated critical, suggesting generally good reliability. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known GMC Safari issues range from $100 to $800, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Common fuel pump failure. The Safari twin-tank models have additional complexity with the tank switching system. Repairs typically run $400-$800. Severity: medium.
The rear Dutch-style doors (upper glass/lower panel) develop broken latches and worn hinges. The upper glass latch can fail to secure, creating a safety hazard, and the lower door hinges wear causing the door to sag. Repairs typically run $100-$350. Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
