1991 GMC Safari Problems: 2 Issues Every Owner Should Know
1991 model year · 0+ owner reports · Updated April 2026
According to Au7o's analysis of 0+ owner reports, the 1991 GMC Safari has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues, repair costs range from $100 to $800. DIY maintenance guides at au7o.io.
All 2 Known Issues
On the 1990-2005 GMC Safari, 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.
Common Symptoms
- Rear door won't latch closed
- Door sags when opened
- Rattling from rear doors
- Upper glass pops open while driving
How to Fix
Replace door latch mechanisms and hinge pins/bushings. The upper glass latch is a safety concern and should be repaired immediately. Lubricate all latch mechanisms and hinges regularly with white lithium grease.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- UpgradeDorman OE-replacement door latch assembly — direct fit (Dorman Door Latch Assembly)
- UpgradeDorman replacement door handle — matches OEM spec (Dorman Door Handle)
On the 1990-2005 GMC Safari, common fuel pump failure. The Safari twin-tank models have additional complexity with the tank switching system.
Common Symptoms
- Stalling
- Hard starting
- Loss of power
How to Fix
Confirm low fuel pressure at the rail with a gauge before replacing parts; the 4.3L V6 should typically show pressure in the mid-50 to low-60 psi range, and a weak pump often causes hard starting, stalling, or loss of power under load. Check the fuel pump relay, fuse, wiring at the tank connector, and on twin-tank models inspect the tank selector/switching valve and related wiring because a fault there can mimic a bad pump. If pressure is low and power/ground are present at the pump, replace the in-tank fuel pump module and strainer, and strongly consider replacing the fuel filter and corroded connector pigtail at the same time; labor usually requires dropping the tank, with typical total repair cost around $500-$1,000 depending on tank configuration and rust. After installation, verify prime pressure, running pressure, and proper tank switching operation on dual-tank systems.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- UpgradeDelphi fuel pump module — OE-quality direct replacement (Delphi Fuel Pump Module)
- UpgradeBosch fuel pump — reliable OEM alternative (Bosch Fuel Pump)