Total Complaints
77 filings
CHEVROLET CAVALIER · model year
77 NHTSA complaints, 8 crash reports for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 1991CHEVROLETCAVALIER carries 77 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 8 crashes, 6 fires, 5 injuries, and 6 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1991 CAVALIER is engine and engine cooling:engine with 6 filings, followed by seats (5) and visibility:windshield wiper/washer (4). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.
NHTSA currently has 57 investigation files overlapping the 1991 CAVALIER, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
77 filings
Crashes Reported
8 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| ENGINE AND ENGINE COOLING:ENGINE | 6 |
| SEATS | 5 |
| VISIBILITY:WINDSHIELD WIPER/WASHER | 4 |
| ELECTRICAL SYSTEM:IGNITION | 3 |
| ELECTRICAL SYSTEM:IGNITION:SWITCH | 3 |
| STEERING:LINKAGES | 2 |
| ELECTRICAL SYSTEM:WIRING | 2 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS | 2 |
| VEHICLE SPEED CONTROL | 2 |
| ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD | 2 |
| FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP | 2 |
| ELECTRICAL SYSTEM:HORN | 2 |
| SEAT BELTS:FRONT:BUCKLE ASSEMBLY | 2 |
| SEATS:FRONT ASSEMBLY:RECLINER | 2 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 2 |
MY SON LOST CONTROL OF A 1991 CHEVROLET CAVALIER AND WAS EJECTED AFTER HE WAS FORCED OFF THE ROAD. WHEN ENTERING THE MEDIAN, HIS CAR WAS SKIDDING BROADSIDE AND EVENTUALLY ROLLED OVER THREE TIMES. AS THE CAR ROLLED, THE DRIVER SIDE DOOR OPENED WHICH DEFEATED THE ABILITY OF THE SEAT BELT TO HOLD HIM INSIDE BECAUSE THE SEAT BELT DESIGN HAD THE SHOULDER HARNESS ANCHORED TO THE TOP OF THE DOOR/WINDOW FRAME AND THE LAP BELT ANCHORED TO THE BOTTOM OF THE DOOR. *JB
THE FIRST PROBLEM I HAVE ENCOUNTERED IS THE POOR BODY OF THE CAR. THE PANELS BELOW THE CAR HAVE COMPLETELY DIMINISHED. ANYTHING REMAINING OF THEM IS EITHER ROTTING AND RUSTING AWAY, OR HAS PAINT REMOVED FROM THEM. THE PAINT IS ALSO COMING OUT OF THE FRONT PLASTIC BUMPER AND FROM THE FRONT HOOD OF THE CAR. SOME RUST IS ALSO APPEARING AT THE SIDES. WHEN I STEP INTO THE HIGHWAY AT THE SPEED OF A MINIMUM 100 KM/H, THIS TRASH IS ANYTHING BUT QUIET. APART FROM THE ENGINE, WHICH IS NOW BROKEN, THE GASKETS OR WHATEVER KEEPS THE AIR OUT DOESN'T KEEP IT OUT. INSTEAD, SOME AIR COMES IN AND THUS MAKING THAT NOISE; LIKE HAVING YOUR WINDOWS OPEN AND GETTING ALL THAT NOISE OF THE AIR. IT'S NO DIFFERENT WHEN CLOSED. THE RUBBER SEAL OF THE DOORS IS EXTREMELY POOR IN THIS REGARD. MY SECOND PROBLEM HAS BEEN THE ENGINE. MY ENGINE'S MOTOR IS BROKEN DOWN. NO MECHANIC CAN FIX IT. I TRIED TO GO THROUGH CHEVROLET AND ONE OF THEIR LOCAL DEALERSHIPS. BUT JUST THE COST OF REFURBISHING MY ENGINE WOULD APROXIMATIL
Mileage: 90,000
THE FIRST PROBLEM I HAVE ENCOUNTERED IS THE POOR BODY OF THE CAR. THE PANELS BELOW THE CAR HAVE COMPLETELY DIMINISHED. ANYTHING REMAINING OF THEM IS EITHER ROTTING AND RUSTING AWAY, OR HAS PAINT REMOVED FROM THEM. THE PAINT IS ALSO COMING OUT OF THE FRONT PLASTIC BUMPER AND FROM THE FRONT HOOD OF THE CAR. SOME RUST IS ALSO APPEARING AT THE SIDES. WHEN I STEP INTO THE HIGHWAY AT THE SPEED OF A MINIMUM 100 KM/H, THIS TRASH IS ANYTHING BUT QUIET. APART FROM THE ENGINE, WHICH IS NOW BROKEN, THE GASKETS OR WHATEVER KEEPS THE AIR OUT DOESN'T KEEP IT OUT. INSTEAD, SOME AIR COMES IN AND THUS MAKING THAT NOISE; LIKE HAVING YOUR WINDOWS OPEN AND GETTING ALL THAT NOISE OF THE AIR. IT'S NO DIFFERENT WHEN CLOSED. THE RUBBER SEAL OF THE DOORS IS EXTREMELY POOR IN THIS REGARD. MY SECOND PROBLEM HAS BEEN THE ENGINE. MY ENGINE'S MOTOR IS BROKEN DOWN. NO MECHANIC CAN FIX IT. I TRIED TO GO THROUGH CHEVROLET AND ONE OF THEIR LOCAL DEALERSHIPS. BUT JUST THE COST OF REFURBISHING MY ENGINE WOULD APROXIMATIL
Mileage: 90,000
THE FIRST PROBLEM I HAVE ENCOUNTERED IS THE POOR BODY OF THE CAR. THE PANELS BELOW THE CAR HAVE COMPLETELY DIMINISHED. ANYTHING REMAINING OF THEM IS EITHER ROTTING AND RUSTING AWAY, OR HAS PAINT REMOVED FROM THEM. THE PAINT IS ALSO COMING OUT OF THE FRONT PLASTIC BUMPER AND FROM THE FRONT HOOD OF THE CAR. SOME RUST IS ALSO APPEARING AT THE SIDES. WHEN I STEP INTO THE HIGHWAY AT THE SPEED OF A MINIMUM 100 KM/H, THIS TRASH IS ANYTHING BUT QUIET. APART FROM THE ENGINE, WHICH IS NOW BROKEN, THE GASKETS OR WHATEVER KEEPS THE AIR OUT DOESN'T KEEP IT OUT. INSTEAD, SOME AIR COMES IN AND THUS MAKING THAT NOISE; LIKE HAVING YOUR WINDOWS OPEN AND GETTING ALL THAT NOISE OF THE AIR. IT'S NO DIFFERENT WHEN CLOSED. THE RUBBER SEAL OF THE DOORS IS EXTREMELY POOR IN THIS REGARD. MY SECOND PROBLEM HAS BEEN THE ENGINE. MY ENGINE'S MOTOR IS BROKEN DOWN. NO MECHANIC CAN FIX IT. I TRIED TO GO THROUGH CHEVROLET AND ONE OF THEIR LOCAL DEALERSHIPS. BUT JUST THE COST OF REFURBISHING MY ENGINE WOULD APROXIMATIL
Mileage: 90,000
WHILE TIGHTENING UP THE LUG NUTS ON THE WHEEL, PIECES OF METAL SHEARED OFF AND DROPPED SMALL PIECES OF METAL ON THE GROUND. *AK THE LUG NUTS IN QUESTION WERE NEWLY PURCHASED. PART#254 ABN 10.9 MANUFACTURED BY R+B INC. *SCC *JB
Mileage: 112,000
WHILE DRIVING DOWN 25-35MPH VEHICLE STALLED OUT AND DIED WITHOUT WARNING. DEALER REPLACED FUEL PUMP FILTER. *AK
NO ONE WAS INJURED. I WAS DRIVING TO WORK AND HAD ALMOST GOT THERE WHEN I HEARD A BANG ON THE SIDE OF THE CAR AND SAW THE TREAD FLY OFF BACK BEHIND FROM MY DRIVERS SIDE FRONT TIRE. TIRE STAYED AIRED UP AS I GOT OFF THE INTERSTATE I80, AND PULLED IN THE PARKING LOT. I GOT OUT TO EXAMINE THE DAMAGE. THE GROUND EFFECTS ON MY DRIVERS SIDE WERE HANGING BY LIKE ONE SCREW. THE TIRE WAS STILL AIRED UP BUT THERE WAS NO TREAD LEFT ON THE TIRE. IT RIPPED HALF OF MY FRONT BUMPER OFF DENTED MY FRONT QUARTER PANEL AND DRIVERS DOOR AND GROUND EFFECTS WERE DESTROYED. FIRESTONE ,P205/60R15 90S M+S FIREHAWK SS10 MY CAR 1991 CHEVROLET, Z24 CAVALIER. *AK
Mileage: 115,000
BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.
BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.
THE REAR WINDOW OF THIS VEHICLE BLEW OUT AS ONE LARGE PIECE (WITH GASKET MATERIAL) AND SHATTERED INTO NUMEROUS PIECES UPON ROAD IMPACT. I SUSPECT THAT THIS IS VERY UNUSUAL AND SHOULD BE DOCUMENTED WITH THE MANUFACTURE & OTHER ORGANIZATIONS. ALSO, IF A PROBLEM EXIST WITH THIS VEHICLE, MAYBE THE MANUFACTURER WILL REPLACE THE PART.
AN '88 BLUE DODGE VAN (VIN 2B6GB113Y3JK56747)CRASHED INTO MY LITTLE GIRLS CAR THE 1991 CAVALIER. EXPERT RECONSTRUCTIONIST (TX DEPT. OF PUBLIC SAFETY) BLAME MY LITTLE GIRL FOR HAVING RAN THE STOP SIGN AND HITTING THE VAN, CAUSING AN INDIRECT DEATH OF THREE AND THE DIRECT DEATH WAS AN ABANDON UTILITY POLE. I DO NOT BELIEVE THAT IF THE CAR WAS TO HIT THE VAN IT WOULD HAVE CAUSED SO MUCH DAMAGE. MY DAUGHTER STATES THAT SHE CAME TO A COMPLETE STOP AND PROCEEDED ENTERING THE INTERSECTION AT 6 MPH. HOW CAN A SMALL CAR DO SO MUCH DAMAGE EVEN IF IT WAS TO HAVE RUNNED THE STOP SIGN. I BELIEVE THAT THE VAN HIT THE CAR CAUSING THE ROOF OF THE CAVALIER TO COLLAPSE AND DOING IRREPAIRABLE DAMAGE TO MY LITTLE GIRLS FRIEND. MY LITTLE GIRL HAD MULTIPLE CONTURSIONS TO THE HEAD WHEN THE ROOF CAVED IN AND HER ANKLE HAD THREE FRACTURES ON HER LEFT ANKLE. THERE WAS EVIDENCE IN THE DRIVER SIDE THAT THE BOTTOM SIDE OF THE DOOR WAS PINGED INWARD AND THE ROOF OVER HER HEAD WAS CAVED IN. LUCKILY THE TWO
WHILE DRIVING A PIN WITHIN THE TILT STEERING WHEEL CAME LOOSE,NEARLY CAUSING LOSS OF STEERING CONTROL. PLEASE GIVE ANY FURTHER DETAILS. *AK
STARTER WAS REPLACED, AND DID NOT FIT PROPERLY IN THE VEHICLE, CAUSING THE STARTER TO COM ELOOSE/ SHAKE. BOLTS NEED TO BE REPLACED. *AK
WINDSHIELD WIPERS WILL QUIT DURING OPERATION, CAUSING POOR VISIBILITY. *AK
WHILE TRAVELING THE BRAKES WOULD MAKE A LOUD NOISE. DEALER AND MANUFACTURER HAVE BEEN CONTACTED. PLEASE PROVIDE FURTHER INFORMANTION. *AK
SEAT BELT GUIDE LOOPS ON PASSENGER SIDE ARE CRACKED. NOTICED RECALL ON WEBSITE (#92V003000). CALLED DEALER & MANUFACTURER & WAS TOLD BY BOTH VEHICLE WAS NOT INCLUDED IN RECALL. OWNER WOULD NEED TO PAY FOR REPAIRS. *AK
I PURCHASED THIS VEHICLE FOR A TEENAGE DRIVER. I HAVE SPENT WELL OVER $L,000 TO BRING IT UP TO SPEED - FUEL FILTER, OIL & AIR FILTERS, SERPENTINE BELT RADIATOR IGNITION SWITCH (KEY & TUMBLER), TIRES, FRONT BRAKE PADS, FRONT BRAKE ROTORS, REAR BRAKE SHOES. IT WILL SOON NEED A NEW MUFFLER, AND MY MECHANIC NOW INFORMS ME THAT THE CYLINDER HEAD GASKET IS LEAKING. HE SAID HE SEES QUITE A FEW OF CAVALIERS WITH THIS PROBLEM AND WONDERS IF THERE IS A SILENT RECALL THAT COULD HELP ME WITH THE POSSIBLE $600.00 COST TO REPAIR. *AK
I PURCHASED THIS VEHICLE FOR A TEENAGE DRIVER. I HAVE SPENT WELL OVER $L,000 TO BRING IT UP TO SPEED - FUEL FILTER, OIL & AIR FILTERS, SERPENTINE BELT RADIATOR IGNITION SWITCH (KEY & TUMBLER), TIRES, FRONT BRAKE PADS, FRONT BRAKE ROTORS, REAR BRAKE SHOES. IT WILL SOON NEED A NEW MUFFLER, AND MY MECHANIC NOW INFORMS ME THAT THE CYLINDER HEAD GASKET IS LEAKING. HE SAID HE SEES QUITE A FEW OF CAVALIERS WITH THIS PROBLEM AND WONDERS IF THERE IS A SILENT RECALL THAT COULD HELP ME WITH THE POSSIBLE $600.00 COST TO REPAIR. *AK
I PURCHASED THIS VEHICLE FOR A TEENAGE DRIVER. I HAVE SPENT WELL OVER $L,000 TO BRING IT UP TO SPEED - FUEL FILTER, OIL & AIR FILTERS, SERPENTINE BELT RADIATOR IGNITION SWITCH (KEY & TUMBLER), TIRES, FRONT BRAKE PADS, FRONT BRAKE ROTORS, REAR BRAKE SHOES. IT WILL SOON NEED A NEW MUFFLER, AND MY MECHANIC NOW INFORMS ME THAT THE CYLINDER HEAD GASKET IS LEAKING. HE SAID HE SEES QUITE A FEW OF CAVALIERS WITH THIS PROBLEM AND WONDERS IF THERE IS A SILENT RECALL THAT COULD HELP ME WITH THE POSSIBLE $600.00 COST TO REPAIR. *AK
I PURCHASED THIS VEHICLE FOR A TEENAGE DRIVER. I HAVE SPENT WELL OVER $L,000 TO BRING IT UP TO SPEED - FUEL FILTER, OIL & AIR FILTERS, SERPENTINE BELT RADIATOR IGNITION SWITCH (KEY & TUMBLER), TIRES, FRONT BRAKE PADS, FRONT BRAKE ROTORS, REAR BRAKE SHOES. IT WILL SOON NEED A NEW MUFFLER, AND MY MECHANIC NOW INFORMS ME THAT THE CYLINDER HEAD GASKET IS LEAKING. HE SAID HE SEES QUITE A FEW OF CAVALIERS WITH THIS PROBLEM AND WONDERS IF THERE IS A SILENT RECALL THAT COULD HELP ME WITH THE POSSIBLE $600.00 COST TO REPAIR. *AK
Loss of motive power due to engine failure
Loss of Motive Power due to the Battery Energy Control Module
Electric Vehicle Battery Fires
Outboard Front Seat Belt Anchor Cable Failure
Fuel Line Leak
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.