1991 Mazda Navajo: Recalls, Problems & MPG
Here are the deets on the 1991 Mazda Navajo: 5 recalls, 39 owner complaints and up to 16 mpg combined.
Recalls
5 vehicle recalls from the manufacturer, plus 1 equipment/tire recall that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Fuel system Vehicle recall #91V020000 · 1991 · 6,424 vehicles
What's wrong: Front heat shield extension May contact the upper front corner of plastic fuel tank damaging or puncturing the fuel tank.
Why it matters: Such fuel tank damage could allow vapor and or fuel toescape; this could result in a fire if a source of ignition is present.
The fix: Relocate heat shield; replace fuel tank if damaged or punctured.
Body & structure Vehicle recall #91V028000 · 1991 · 10,000 vehicles
What's wrong: Rear bumper May be susceptible to fatigue cracking under extended trailer tow service when using a bumper mounted trailer hitch.
Why it matters: Bumper could separate from vehicle when using a bumpermounted trailer hitch ball.
The fix: Install two additional brackets, one additional bar and associated fasteners to prevent bumper separation.
Transmission & drivetrain Vehicle recall #91V189001 · 1991 · 33,540 vehicles
What's wrong: When the automatic transmission shift lever is placed in the park position, the park pawl does not always abut or engage the park gear.
Why it matters: Driver May believe the vehicle is safely engaged in parkwhen the gear is not truly engaged. This can lead to the vehicle jumping out ofgear unintentionally, vehicle rollaway when parked on a sloped surface, andinadvertent motion when the vehicle is started. All of these conditions canresult in a…
The fix: Repair the transmission with a new park pawl.
Brakes (hydraulic) Vehicle recall #96V024002 · 1996 · 2,500 vehicles
What's wrong: The studs which attach the brake master cylinder to the power brake vacuum booster assembly can develop stress corrosion cracking after being operated for an extended period of time in the southern california location.
Why it matters: If a crack occurs, it could result in one or both studs fracturing. The master cylinder could then separate from the vacuum booster, when the brakes are applied, preventing the service brakes from fully activating increasing the risk of a vehicle accident.
The fix: Dealers will replace the power brake vacuum booster assembly.
Body & structure Vehicle recall #97V235002 · 1998 · 23,000 vehicles
What's wrong: The sunroof glass panel assembly can separate while the vehicle is moving due to incorrect hinge engagement. This was caused by improper sunroof installation of the glass panel.
Why it matters: Unexpected separation of the sunroof glass panel could possibly distract the driver increasing the risk of a vehicle crash or loss of vehicle control.
The fix: Owners will be provided with an instruction booklet which thoroughly outlines, with illustrations, the proper procedures for the removal, storage, and reinstallation of the sunroof's glass panel. A warning label for attachment to the sunroof's latch knob will also be provided to the owners.
1 aftermarket equipment / tire recall replacement parts sold to fit this car, not the car itself
Tires Tire recall #00T005000 · 2000 · 14,400,000 vehicles
What's wrong: Tire description: firestone wilderness at, size p235/75r15, produced at the decatur, illinois tire plant and all firestone radial atx and radial atx II tires, size p235/75r15. Operation of these tires at low inflation pressures, high speed, and in hot weather, can contribute to separation of the tire tread.
Why it matters: If the tread separates from the tire, the driver can lose control of the vehicle, possibly resulting in a crash causing injury or death.
The fix: The replacement/reimbursement program for this campaign expired on August 29, 2001. However, customers should contact firestone customer service at 1-800-465-1904 for possible assistance.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 0 mention a fire, 4 injuries and 0 deaths were reported.
What owners describe
- Tires (8): the most common themes are tire tread / blowout (8).
- Transmission & drivetrain (7): no single recurring theme in the descriptions.
- Electrical (6): the most common themes are electrical failure (6).
- Brakes (hydraulic) (5): no single recurring theme in the descriptions.
The 1991 Mazda Navajo has 39 owner complaints, ranking #2 of 5 Navajo model years for complaints (1.6× the average Navajo year). Complaints peaked in 1996 (12 filed that year). The typical problem showed up when the car was about 5 years old, at a median of 66,000 miles. Neighboring years: 1990 (1 complaints, 0 recalls), 1992 (12 complaints, 3 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 4.0 L 6-cyl | Automatic 4-spd | 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | Regular |
| 4.0 L 6-cyl | Manual 5-spd | 4-Wheel or All-Wheel Drive | 15 | 19 | 16 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 1991 Mazda Navajo.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
From $19.99/mo · $39.99/yrOEM procedures, specs and recall/TSB info, the same source many shops use.
From $19.99/mo · $59.99/yrStep-by-step photos written from a real teardown. Great for first-timers.
Books ~$30–$40 · AllAccess $34.99/moHeads up: we may earn a commission if you buy through these links, at no extra cost to you. Prices checked 2026-10 and can change. We never host or link to pirated manuals. Disclosure
FAQ
Does the 1991 Mazda Navajo have any recalls?
Yes. NHTSA lists 5 vehicle recalls for the 1991 Mazda Navajo, plus 1 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 1991 Mazda Navajo problems?
Owners have filed 39 complaints with NHTSA. The most-reported areas are tires (8), transmission & drivetrain (7), electrical (6).
What gas mileage does the 1991 Mazda Navajo get?
EPA ratings run up to 16 mpg combined (4.0 L, Automatic 4-spd), across 2 engine and transmission combos.
Where can I get a 1991 Mazda Navajo repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.