Back to search

1999 PLYMOUTH VOYAGER

2.4L I4•FWD•AUTOMATIC•gas
5-Year Cost of Ownership
$39,597 maintenance + known platform issues
~$7,919/yr · 660¢/mile equivalent · $31,743 maintenance + $7,154 expected platform issues
Compare this engine
vs
3.0L V6
vs
3.3L V6
Common Problems & Known Issues

The 1999 Plymouth Voyager is part of Chrysler's third-generation minivan platform, notorious for transmission failures and significant 2.4L engine problems. Budget for major drivetrain work if buying used.

41TE Automatic Transmission Failure

Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Harsh or delayed 2-3 shift, especially when cold, Slipping between gears or loss of reverse, Limp mode (stuck in second gear), Transmission fluid contamination in radiator overflow (cooler leak)
Fix: The 41TE four-speed is a weak point across all Chrysler minivans. Internal clutch pack and solenoid failures are epidemic. Rebuild runs 12-18 hours labor, or 8-12 hours for remanufactured swap. The transmission oil cooler integrated into the radiator commonly fails internally, mixing coolant and ATF and destroying the transmission — this should be addressed preventively or with external aftermarket cooler. Full rebuild or replacement required.
Estimated cost: $2,200-3,800

2.4L Engine Sludge and Bearing Failure

Common · high severity
Typical onset: 60,000-120,000 mi
Symptoms: Heavy oil consumption (quart per 500-1,000 miles), Loud rod knock or main bearing noise on cold start, Low oil pressure warning light, Blue smoke from exhaust, Engine runs rough or misfires
Fix: The 2.4L DOHC has poor oiling design and piston ring durability. Oil sludge accumulates in the head, starving bearings. Late maintenance makes this worse. Typical fix is short block replacement (16-22 hours) or full rebuild with new pistons, rings, bearings, and head gasket work (24-30 hours). Many owners experience catastrophic failure requiring engine replacement.
Estimated cost: $3,200-5,500

Head Gasket Failure (3.0L Mitsubishi V6)

Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: External coolant leaks at rear of engine, White smoke from exhaust on startup, Overheating or fluctuating temperature gauge, Coolant loss without visible external leak, Milky oil on dipstick or oil cap
Fix: The 3.0L Mitsubishi V6 (not the 3.3L) has a tendency for rear head gasket leaks due to inadequate clamping force and thermal cycling. The rear bank is extremely difficult to access in this transverse installation. Both head gaskets, timing belt, water pump, and resurfacing typically done together. 18-24 hours labor in this cramped engine bay.
Estimated cost: $2,800-4,200

Lower Ball Joint and Control Arm Failure

Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Clunking noise over bumps from front end, Steering wander or poor return to center, Uneven or feathered front tire wear, Visible play when prying on tire at 6 and 12 o'clock
Fix: Ball joints are not serviceable separately on this platform — entire lower control arm assembly must be replaced. Common issue across all Chrysler minivans of this era. Both sides should be done together. 3-4 hours labor for the pair, plus alignment.
Estimated cost: $450-750

Intake Manifold Gasket Leak (3.3L V6)

Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Coolant leak from front-center of engine, Slight overheating or low coolant warnings, Visible green residue around intake manifold base, Rough idle when cold
Fix: The 3.3L V6 has a plastic intake manifold with gaskets that deteriorate and leak coolant externally. Must remove upper plenum and intake. While in there, replace thermostat and check coolant hoses. 5-7 hours labor.
Estimated cost: $600-950

Corroded Fuel Filler Neck

Occasional · low severity
Symptoms: Fuel smell near rear quarter panel, Check engine light with EVAP leak codes (P0442, P0456), Visible rust or holes in filler tube, Fuel gauge reading erratic
Fix: The steel fuel filler neck rusts through from the inside out, especially in salt-belt states. This triggers EVAP codes and can leak fuel. Replacement requires dropping fuel tank or accessing from above with interior removal. 3-5 hours labor depending on rust severity.
Estimated cost: $350-650

ABS Pump/Module Failure

Occasional · medium severity
Typical onset: 120,000-180,000 mi
Symptoms: ABS and brake warning lights illuminated constantly, Groaning or whining noise from ABS pump under hood, Loss of ABS function (brakes still work, but no ABS), Firm brake pedal but excessive pedal travel
Fix: The Bendix-10 ABS module is known for internal corrosion and pump motor failure. Diagnosis requires scan tool. Used or remanufactured unit is typical fix. Bleeding the ABS system properly requires scan tool activation. 2-3 hours labor.
Estimated cost: $600-1,200
Owner tips
  • Change transmission fluid every 30,000 miles with Mopar ATF+4 only — never flush, drain and fill only
  • Install an external transmission oil cooler to bypass the failure-prone radiator cooler
  • On 2.4L engines, use full synthetic oil and change every 3,000-4,000 miles to minimize sludge
  • Inspect the transmission oil cooler lines at radiator for pink fluid mixing — address immediately to save transmission
  • Replace timing belt and water pump together at 90,000-100,000 miles on V6 engines
Hard pass unless extremely cheap and you're handy — transmission and 2.4L engine are ticking time bombs that will cost more to fix than the van is worth.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
593 jobs across 17 categories
Building an app?
Free API access to all this data — 50 requests/day, no card required.
Get an API key →
Run a shop?
Manage repairs, estimates, and customers with ShopBase — $249/mo, all features included. Built by the same team.
Try ShopBase →