The 1996 Chrysler Cirrus was Chrysler's first-generation cloud car with significant transmission vulnerabilities and notorious head gasket failures on the 2.4L engine. The platform suffers from premature lower ball joint wear and fuel pump issues that can leave you stranded.
41TE Automatic Transmission Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Delayed or harsh engagement into drive or reverse, Slipping between gears, especially 2nd-3rd shift, No movement in any gear after warm-up, Burnt transmission fluid smell, dark red or brown fluid
Fix: The 41TE (A604) transmission is the Achilles heel — internal clutch pack and solenoid pack failures are epidemic. Rebuilds rarely last without upgraded parts. Factory trans cooler is undersized, leading to overheating. Expect 12-16 hours for R&R and rebuild, or 8-10 hours for a used replacement.
Estimated cost: $2,200-3,800
2.4L DOHC Head Gasket Failure
Common · high severity
Typical onset: 60,000-120,000 mi
Symptoms: White smoke from exhaust, especially on cold start, Coolant loss with no visible leaks, Overheating or fluctuating temperature gauge, Milky oil on dipstick or oil cap, Rough idle and misfires after coolant intrusion
Fix: The 2.4L engine has thin head gasket material and tends to blow between cylinders 2-3 or into coolant passages. Head warpage is common, requiring machining. Job involves timing belt replacement while you're in there. 10-14 hours labor, includes resurfacing head.
Estimated cost: $1,800-2,800
Lower Ball Joint Separation
Common · high severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking noise over bumps from front end, Steering wander or pulling to one side, Excessive play when rocking wheel at 12 and 6 o'clock, Uneven tire wear on inside edge
Fix: Factory ball joints are pressed into stamped lower control arms and fail prematurely — NHTSA investigated this twice. The joint can separate catastrophically, causing wheel collapse. Replace entire control arm assemblies (pressed joints aren't serviceable in the field reliably). 2.5-3.5 hours per side including alignment.
Estimated cost: $450-750
In-Tank Fuel Pump Failure
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: No-start condition with crank but no fire, Stalling during acceleration or when fuel level drops below half, Whining or buzzing noise from rear seat area, Intermittent starts requiring multiple key cycles
Fix: Fuel pump assembly sits in the tank and is prone to motor burnout and sock filter clogging. Access requires dropping the tank (no convenient access panel). Replace entire pump module, not just the motor. 3-4 hours labor.
Estimated cost: $500-800
Transmission Mount Collapse
Occasional · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunk when shifting from park to drive or reverse, Excessive engine movement visible from engine bay during acceleration, Vibration through shifter and floorboard, Chassis shudder on hard acceleration
Fix: The front transmission mount (dogbone) deteriorates quickly due to transverse engine torque and poor rubber compound. Engine will rock excessively and stress CV axles. Relatively easy fix at 1-1.5 hours labor.
Estimated cost: $180-300
ABS Pump/Controller Module Failure
Occasional · medium severity
Symptoms: ABS warning light illuminated constantly, Pulsing brake pedal during normal stops (false ABS activation), Extended stopping distances, No ABS function during panic stops
Fix: The Bendix 10 ABS unit suffers internal valve body and pump motor failures. Conventional braking still works but no ABS. Used modules need programming. 2-3 hours for replacement and bleeding.
Estimated cost: $600-1,200
Intake Manifold Gasket Leak (2.5L V6)
Occasional · low severity
Typical onset: 80,000-130,000 mi
Symptoms: Coolant seepage at front of engine below throttle body, Rough idle when cold, Sweet coolant smell from engine bay, Slight coolant loss over time
Fix: Upper and lower intake gaskets on the 2.5L Mitsubishi V6 degrade and leak coolant externally or cause vacuum leaks. Requires removing upper plenum and throttle body. 4-5 hours labor.
Estimated cost: $450-700
Owner tips
Change transmission fluid every 30,000 miles with ATF+4 only — this can extend 41TE life significantly
Install an auxiliary transmission cooler if towing or in hot climates
Inspect lower ball joints annually after 60,000 miles — play in these is a safety emergency
2.4L engines: watch coolant level religiously and address head gasket seepage immediately before it becomes catastrophic
Replace fuel filter every 50,000 miles to reduce fuel pump strain
Hard pass unless under $1,500 with documented recent transmission rebuild and ball joint replacement — too many expensive catastrophic failures waiting to happen.
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.
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SUSPENSION:FRONT:CONTROL ARM:LOWER ARM · 10E059000
2010-12-27
FEDERAL-MOGUL IS RECALLING CERTAIN REPLACEMENT CONTROL ARM ASSEMBLIES, PART NUMBERS K7425, 10945, FA4510X, K7427, 10946, AND FA4611X, SOLD FOR USE ON VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE BALL JOINT ON THE CONTROL ARM ASSEMBLY CAN FAIL CAUSING THE BALL STUD TO WEAR THROUGH THE CONTROL ARM HOUSING RESULTING IN NOISE AND/OR SEPARATION OF THE BALL STUD FROM THE HOUSING.
Consequence: IF THERE IS A SEPARATION OF THE BALL STUD FROM THE HOUSING, THE DRIVER CAN LOOSE STEERING CONTROL, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: FEDERAL-MOGUL WILL NOTIFY OWNERS OF RECORD AND REPLACE THE AFFECTED CONTROL ARMS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 28, 2011. OWNERS MAY CONTACT FEDERAL-MOGUL AT 1-877-489-6659.
QUALIS AUTOMOTIVE IS RECALLING CERTAIN AFTERMARKET BALL JOINTS SOLD FOR USE ON CERTAIN PASSENGER VEHICLES. THE SOCKET MAY HAVE BEEN EXCESSIVELY HARDENED WHICH COULD CAUSE IT TO CRACK NEAR THE RETAINING RING GROOVE ALLOWING THE BALL STUD TO SEPARATE UNDER IMPACT LOAD. THE SUBJECT BALL JOINTS WERE SOLD AS FOUR PART NUMBERS, D10945, D10946, G10945, AND G10946. THE AFFECTED CONTROL ARMS, D10945 AND D10946, ARE STAMPED WITH THE FOLLOWING DATES ON THE BALL JOINTS: 134308, 135708, 100109, 102709, 104109, 105509, 107609, 108909, 110309, 113209, AND 116609. THE G10945 AND G10946 ARE THE SAME PART AS THE D10945 AND D10946 RESPECTIVELY. THEY ARE LABELED DIFFERENTLY DEPENDING ON THE AFTERMARKET CUSTOMER.
Consequence: SEPARATION OF THE BALL STUD FROM THE SOCKET OF THE BALL JOINT HOUSING WOULD ALLOW THE CONTROL ARM TO COLLAPSE AND THE WHEEL TO FOLD IN CAUSING LOSS OF STEERING CONTROL, POSSIBLY RESULTING IN A CRASH.
Remedy: QUALIS AUTOMOTIVE WILL REPLACE THE BALL JOINTS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 9, 2009. OWNERS MAY CONTACT QUALIS AUTOMOTIVE AT 1-800-493-4128.
CERTAIN AIRTEX FUEL PUMP MODULES, P/NOS. E7089M, E7094M, E7113M, AND E7129M, MANUFACTURED BETWEEN JUNE 1 AND SEPTEMBER 24, 2006. THESE FUEL PUMP MODULES WERE SOLD AS AFTERMARKET FOR USE IN CERTAIN DAIMLERCHRYSLER VEHICLES LISTED ABOVE. SILICONE MATERIAL USED IN MANUFACTURE OF THE FLAPPER VALVE WAS OUT-OF-SPECIFICATION, LEADING TO EXCESS SWELL OF THE FLAPPER VALVE RESTRICTING THE FLOW OF FUEL TO THE FUEL PUMP MODULE.
Consequence: FUEL RESTRICTION COULD RESULT IN LOSS OF POWER AND/OR ENGINE STALL, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: AIRTEX WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMP MODULES FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT AIRTEX TOLL-FREE AT 1-866-867-3759.
CERTAIN TIGAS FUEL PUMP MODULES MANUFACTURED BETWEEN JUNE 1 AND SEPTEMBER 24, 2006, SOLD UNDER VARIOUS BRAND NAMES AND P/NOS. THESE FUEL PUMP MODULES ARE SOLD AS AFTERMARKET FOR USE IN CERTAIN DAIMLERCHRYSLER VEHICLES LISTED ABOVE. SILICONE MATERIAL USED IN MANUFACTURE OF THE FLAPPER VALVE WAS OUT-OF-SPECIFICATION, LEADING TO EXCESS SWELL OF THE FLAPPER VALVE RESTRICTING THE FLOW OF FUEL TO THE FUEL PUMP MODULE.
Consequence: FUEL RESTRICTION COULD RESULT IN LOSS OF POWER AND/OR ENGINE STALL, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: TI AUTOMOTIVE WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMP MODULES FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 6, 2006. OWNERS MAY CONTACT TI AUTOMOTIVE TOLL-FREE AT 1-877-461-1834.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:FLOOR SHIFT · 04V021000
2004-01-13 · EA03011
ON CERTAIN PASSENGER VEHICLES, THE FLOOR SHIFTER IGNITION-PARK INTERLOCK MAY FAIL AND ALLOW THE SHIFTER TO BE MOVED OUT OF THE PARK POSITION WITH THE KEY REMOVED. AN INOPERATIVE INTERLOCK MAY ALSO ALLOW THE KEY TO BE REMOVED WHEN THE SHIFTER HAS NOT BEEN PLACED IN THE PARK POSITION.
Consequence: EITHER CIRCUMSTANCE MAY RESULT IN THE VEHICLE ROLLING AWAY WITHOUT WARNING.
Remedy: DEALERS WILL INSTALL A NEW LOAD-LIMITING PUSH ROD INTO THE FLOOR SHIFTER LEVER OF THE AFFECTED VEHICLES. OWNER NOTIFICATION BEGAN ON JUNE 14, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCH · 98V183000
1998-08-06 · EA98014
VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS. THE ADJUSTMENT OF THE CABLE CONNECTING THE CONSOLE SHIFTER MECHANISM TO THE IGNITION KEY CAN CAUSE A TRAPPED KEY CONDITION WHICH CAN RESULT IN A LOW FORCE REQUIRED TO DEPRESS THE SHIFT BUTTON. A COMBINATION OF APPLYING A MIS-ADJUSTED RELEASE BUTTON WITH A LOW FORCE ATTEMPT TO SHIFT OUT OF PARK WITH THE KEY IN THE LOCKED POSITION, CAN BREAK THE CONNECTING PIN IN THE SHIFTER.
Consequence: IF THIS HAPPENS, THE "IGNITION-PARK" INTERLOCK SYSTEM WILL BE NONFUNCTIONAL.
Remedy: DEALERS WILL INSPECT FOR PROPER OPERATION OF THE SYSTEM. ANY VEHICLES THAT ARE NOT FUNCTIONAL AFTER THE INSPECTION WILL HAVE THE SHIFT MECHANISM AND CABLE REPLACED WITH A "SELF-ADJUSTING" DESIGN.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE LOWER CONTROL ARM BALL JOINT CAN SEPARATE DUE TO LOSS OF LUBRICATION.
Consequence: SEPARATION OF THE BALL JOINT COULD CAUSE A LOSS OF STEERING CONTROL INCREASING THE RISK OF A VEHICLE CRASH.
Remedy: DEALERS WILL INSPECT THE BALL JOINT END HOUSING COVER SEAL FOR LEAKAGE WITH A HIGH PRESSURE AIR TESTER AND THE RUBBER BOOT WILL BE VISUALLY INSPECTED FOR DAMAGE. IF THE COVER SEAL LEAKS OR THE BOOT IS DAMAGED, THE LOWER CONTROL ARM WILL BE REPLACED.
STRUCTURE:BODY:HOOD:HINGE AND ATTACHMENTS · 97V095000
1997-06-06
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE SECONDARY HOOD LATCH SPRING CAN DISENGAGE FROM ITS RETENTION HOLE IF THE HOOD IS SLAMMED SHUT.
Consequence: IF THIS CONDITION OCCURS SIMULTANEOUSLY WITHOUT ENGAGING THE PRIMARY LATCH, THE HOOD WOULD NOT BE RESTRAINED INCREASING THE RISK OF A VEHICLE CRASH.
Remedy: DEALERS WILL REPLACE THE SECONDARY HOOD LATCH SPRING WITH A LONGER END HOOK SPRING.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 96V075000
1996-05-03
THE BRAKE MASTER CYLINDER CAN LEAK BRAKE FLUID DUE TO A DAMAGED DOUBLE LIP REAR PISTON SEAL.
Consequence: BRAKE FLUID LEAKAGE CAN RESULT IN DIMINISHED EFFECTIVENESS OF ONE HALF OF THE SPLIT BRAKE SYSTEM. THE INSTRUMENT PANEL WARNING LIGHT(S) WILL SIGNAL SYSTEM IMPAIRMENT PRIOR TO PARTIAL BRAKE SYSTEM LOSS.
Remedy: DEALERS WILL REPLACE THE REAR BRAKE MASTER CYLINDR PISTON ASSEMBLY.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP · 96V074000
1996-05-02
CORROSION OF THE ABS HYDRAULIC CONTROL UNIT CAN CAUSE THE SOLENOID VALVES TO STICK IN THE OPEN POSITION.
Consequence: IF EITHER FRONT WHEEL VALVE STICKS, THE VEHICLE WOULD SWERVE FROM A STRAIGHT STOP WHEN THE BRAKES ARE APPLIED.
Remedy: DEALERS WILL INSTALL A PLATE AND SILICONE GREASE INJECTED INTO THE SOLENOID CAVITY TO ELIMINATE THE POTENTIAL FOR THIS CONDITION.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE · 96V006000
1996-01-11
IN CERTAIN VEHICLES, THE ENGINE CYLINDER HEAD OIL GALLEY PLUG DOES NOT SEAL PROPERLY AND ENGINE CYLINDER HEAD OIL IS NOT ADEQUATELY RETAINED.
Consequence: INADEQUATE SEALING AND RETENTION OF THE PLUG CAN RESULT IN OIL LEAKAGE WHICH COULD CAUSE A FIRE IN THE ENGINE COMPARTMENT.
Remedy: DEALERS WILL INSTALL AN EXPANSION PLUG AND RETAINING BRACKET OVER THE CYLINDER HEAD OIL GALLEY PLUG.
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