1991 Chevrolet 3500 Pickup Problems

RepairPal has identified the most common problems with the 1991 Chevrolet 3500 Pickup as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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15
Known Problems

The distributor may develop internal faults. This can cause a rough running engine or stalling condition, the Check Engine Light may or may not illuminate. Our technicians tell us that the distributor should be overhauled or replaced to correct this concern.

On the 4L80-E Transmission (Diesel and 7.4L gas engine), Transmission fluid may leak through the electrical connector on the side of the transmission, damaging the wire harness and causing the transmission to shift erratically. Our technicians tell us there are updated shift solenoids, an internal  transmission harness, and a connector pigtail available to correct this fault.

The air conditioning compressor may develop an abnormal noise and require replacement. We recommend that whenever an AC compressor is being replaced for a noise condition, a filter kit should be installed to prevent any metal particles in the system from damaging the new compressor.

An engine vacuum leak may develop from the throttle body gasket causing a higher than normal idle speed. Failed gaskets should be replaced.

The fuel pump may fail causing the engine to stall and not restart. Our technicians recommend replacing the fuel filter every 30,000 miles to help prevent undue strain on the fuel pump.

The anti-lock brake system (ABS) front wheel speed sensors are prone to failure. When a sensor fails, the ABS warning light may illuminate and/or the ABS system may activate erratically.

Power brake systems using "hydro-boost" may leak power steering fluid from the hydro-boost unit located behind the brake master cylinder. Replacement of the hydro-boost unit is the common repair to correct this concern.

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

One or more heater & AC (HVAC) air delivery and/or temperature mode door actuator may fail. This can result in incorrect air delivery or temperature. If this occurs, fault code(s) stored in the HVAC control module should be available to assist with diagnoses.

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Running the engine with a coolant/oil mix may result in engine damage. Replacing the intake manifold gasket should correct this issue.

A coolant leak may develop from the water pump. The engine may overheat as a result of the coolant loss. A leaking water pump should be replaced.

The quick-connect fittings for the heater hoses tend to leak engine coolant. This problem commonly occurs because the metal housing has become brittle, which can break and cause leaks.

The windshield wipers may not work intermittently due to a faulty wiper motor control board. Our technicians tell us that lightly taping on the wiper motor when the fault occurs should temporarily get the wipers working again. Some vehicles were recalled for this problem and some were not. You will need to check with your local dealer to find out if a specific vehicle was included.

The inside and outside door handles are prone to breaking.

The power door lock actuators may become slow to operate or stop working completely and require replacement.