According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Toyota Land Cruiser has 3 documented known issues, with 1 rated critical. The most serious is Body and frame rust: rear quarter panels, rockers, and frame rails ($500-$6,000 repair). Across all issues with published estimates, repair costs range from $300 to $6,000. DIY maintenance guides at au7o.io.
On the 1990-1999 Toyota Land Cruiser, in salt-belt and coastal climates, corrosion is the primary killer of these otherwise-durable trucks. The rear quarter panels are a notorious rot spot: the rear wheel-arch extension acts as a bucket that traps wet mud and road salt, and water intrusion past the rear side-window and tailgate seals (with no drain holes in the spot-welded section) rusts the panels from the inside out. Owners should also inspect the frame rails, body mounts, rocker panels, and wheel wells. Because mechanical parts commonly outlast the sheet metal and frame, rust condition is often the deciding factor in whether a 1990s Land Cruiser is worth restoring.
Bubbling/perforation at rear wheel-arch and quarter panels
Rusty rocker panels and body-mount areas
Flaking/scaling frame rails
Water/dampness in rear cargo area
How to Fix
Cut out and weld in replacement quarter-panel/rocker repair sections (reproduction doglegs and OEM-style panels are available), fix the water-intrusion source (reseal windows and tailgate), and treat/cavity-wax the frame. For surface frame rust, media-blast and coat; for perforated frame or body mounts, weld in new steel. Preventive rinsing of the rear arches and undercoating markedly slows progression.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
CruiserYard rust-free used FJ80/FZJ80 right rear quarter panel
rust-free donor panel for extensive right-quarter corrosion when a full section is justified Fitment/availability: 1991-1997 FJ80/FZJ80/LX450 right/passenger-side rear quarter; verify flare, molding, cut boundaries and freight before pur…
Toyota 61031-60010/60011 genuine right rear-lower quarter extension
lower dogleg/quarter extension when corrosion is localized to the matching early 80-series panel Fitment/availability: VIN- and production-date-confirmed FJ80/FZJ80 right rear-lower quarter extension; early 61031-60010 is replaced by 610…
Toyota 61114-60020 genuine left upper quarter/side outer panel
100-series left upper-quarter section, not an 80-series repair panel Fitment/availability: VIN-confirmed 1998-1999 Land Cruiser 100-series left/driver-side upper quarter within this issue; seller catalog continues the part through 2007 F…
On the 1990-1999 Toyota Land Cruiser, like most vehicles of the era, the Land Cruiser's factory radiator uses plastic end tanks crimped to an aluminum core. With age and heat cycling the plastic becomes brittle and cracks, and on these trucks the leak very commonly originates near the rectangular boss on the top tank where the part number is stamped. It affects both the 80-series and the early 100-series and often appears around 80,000-100,000 miles; owners frequently report the tank 'suddenly lets go' rather than showing a slow drip first, which risks an overheat that can then damage the head gasket. A failing fan clutch (another common 80-series item) compounds the overheat risk. This makes a proactive radiator replacement a common preventive step on any high-mileage example.
Visible crack/leak at top radiator tank near part-number boss
Coolant loss and low-coolant warnings
Steam from radiator area
How to Fix
Replace the radiator (OEM/Denso or a quality all-metal aftermarket unit), and refresh the thermostat, upper/lower hoses and coolant while access is open. Inspect the fan clutch at the same time. Given the head-gasket downstream risk, many owners replace the radiator preventively rather than waiting for the tank to split.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 16400-66040 genuine radiator assembly
early/mid 80-series radiator replacement after a leak, restriction or tank/crimp failure is confirmed Fitment/availability: VIN-confirmed 1992-1996 Land Cruiser 3F-E 4.0L or 1FZ-FE 4.5L branch; production and transmission-cooler configur…
late 80-series radiator branch Fitment/availability: 1995-1997 Land Cruiser 1FZ-FE 4.5L FZJ80 branch; replaces 16400-66080 and still requires VIN confirmation where catalog years overlap 16400-66040 Fitment/availability: Live direct prod…
Toyota 16400-50210 genuine radiator assembly, superseded to 16400-50360
early 100-series radiator branch, not an 80-series part Fitment/availability: 1998-1999 Land Cruiser 2UZ-FE 4.7L 100-series within this issue; seller catalog continues the superseded assembly through 2003 Fitment/availability: Live direc…
On the 1990-1997 Toyota Land Cruiser, the 80-series uses a solid front axle with full-time 4WD, so the front birfield (Birfield-type CV) joints and steering knuckles are under constant load and require periodic service that many owners skip. Toyota specifies repacking the birfields/knuckles roughly every ~90,000 miles (with knuckle grease/wheel-bearing intervals in between). When neglected, symptoms include clicking/knocking on tight turns, grease slung on the inside of the wheels, and leaking inner axle/knuckle seals that let gear oil and grease mix and escape. A common servicing error is pumping grease into the square check plug (a level-check plug only), which never reaches the actual joint. Fast-wearing or repeatedly leaking inner seals can also indicate a bent/warped front axle housing. A pre-April-1994 vs later drive-plate thickness change means early and late birfields are not freely interchangeable.
Common Symptoms
Clicking or knocking during tight low-speed turns
Grease flung onto inner wheel/tire
Gear oil / grease leaking from front knuckles
Front-end vibration or play
How to Fix
Perform a full front axle 'knuckle rebuild': disassemble the knuckles, clean and inspect birfields, install new inner axle seals, wiper (felt) seals, knuckle bearings and gaskets, and repack birfields and knuckles with the correct moly grease. Swapping birfields side-to-side extends their life since they wear on one side. Address a warped housing if seals wear abnormally fast, and use the correct-era birfields when replacing. Many owners DIY this; a shop rebuild of both sides is straightforward but labor-intensive.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Sumo Gear FA9097 80-series front knuckle rebuild kit
both-side knuckle bearings, inner seals, wipers, gaskets, retainers, shims and lock washers for the complete service Fitment/availability: January 1990-January 1998 80/81-series Land Cruiser and LX450; one kit per vehicle, with optional …
What are the most common Toyota Land Cruiser problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Toyota Land Cruiser has 3 documented issues. The most frequently reported are: Body and frame rust: rear quarter panels, rockers, and frame rails, OEM radiator plastic end-tank cracking, Front axle knuckle service neglect / birfield wear and knuckle seal leaks. Of these, 1 is rated critical and should be addressed promptly.
Is the Toyota Land Cruiser reliable?
The 1991 Toyota Land Cruiser has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Body and frame rust: rear quarter panels, rockers, and frame rails. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Toyota Land Cruiser problems?
Repair costs for known Toyota Land Cruiser issues range from $300 to $6,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Body and frame rust: rear quarter panels, rockers, and frame rails, typically costs $500-$6,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 1990-1999 Toyota Land Cruiser Body and frame rust: rear quarter panels, rockers, and frame rails?
In salt-belt and coastal climates, corrosion is the primary killer of these otherwise-durable trucks. The rear quarter panels are a notorious rot spot: the rear wheel-arch extension acts as a bucket that traps wet mud and road salt, and water intrusion past the rear side-window a… Repairs typically run $500-$6,000. Severity: high.
What is the 1990-1999 Toyota Land Cruiser OEM radiator plastic end-tank cracking?
Like most vehicles of the era, the Land Cruiser's factory radiator uses plastic end tanks crimped to an aluminum core. With age and heat cycling the plastic becomes brittle and cracks, and on these trucks the leak very commonly originates near the rectangular boss on the top tank… Repairs typically run $300-$800. Severity: medium.
What is the 1990-1997 Toyota Land Cruiser Front axle knuckle service neglect / birfield wear and knuckle seal leaks?
The 80-series uses a solid front axle with full-time 4WD, so the front birfield (Birfield-type CV) joints and steering knuckles are under constant load and require periodic service that many owners skip. Toyota specifies repacking the birfields/knuckles roughly every ~90,000 mile… Repairs typically run $300-$1,500. 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.
