The 1992 Plymouth Voyager is a first-generation minivan known for catastrophic automatic transmission failures and 3.0L Mitsubishi V6 engine self-destruction. Budget for major drivetrain work if buying used.
Symptoms: Harsh shifting or refusal to shift out of second gear (limp mode), Slipping between gears, delayed engagement from Park, Burnt transmission fluid smell, metal shavings on dipstick, Complete loss of forward gears, stuck in neutral
Fix: The A604 Ultradrive was Chrysler's first electronic 4-speed auto and notoriously fragile. Solenoid pack failures are common but often mask deeper clutch pack damage. Most need full rebuild or replacement. Expect 8-12 hours labor for R&R plus rebuild time. Used units fail just as often—rebuild with updated parts or swap to older 3-speed if possible.
Estimated cost: $1,800-3,200
3.0L Mitsubishi V6 Head Gasket and Bottom-End Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: White smoke from exhaust, persistent coolant loss with no visible leaks, Overheating, bubbles in coolant reservoir, Milky oil on dipstick or cap, coolant in oil pan, Loud rod knock on cold start, oil pressure drop
Fix: The 3.0L V6 suffers head gasket leaks that allow coolant into cylinders, washing cylinder walls and killing bearings. Once knock starts, it's terminal—needs full rebuild or short block. Head gaskets alone run 10-14 hours; full rebuild is 20-28 hours. Not worth doing on a high-mileage example. The 2.4L I4 and 3.3L V6 are significantly more durable.
Estimated cost: $2,400-5,500
Transmission Oil Cooler Line Leaks and Corrosion
Common · medium severity
Typical onset: 70,000-130,000 mi
Symptoms: Transmission fluid spots under vehicle, low fluid level, Rust-brown staining on cooler lines near radiator, Overheating transmission after highway driving, Fluid dripping from front of vehicle when parked on incline
Fix: Steel cooler lines rust through where they connect to the radiator, especially in salt states. Leaks starve the already-weak A604 transmission. Replace lines and fittings as a set—don't try to patch. Also check radiator-mounted cooler for internal leaks (coolant mixing with ATF is catastrophic). Lines are 2-3 hours labor, cooler adds another 3-4 if radiator must come out.
Estimated cost: $300-900
Liftgate Strut and Latch Failures
Common · low severity
Symptoms: Liftgate drops suddenly when opened, won't stay up, Latch won't release from inside or outside, glass pops open instead, Rattling or clunking from liftgate while driving, Visible fluid leaking from strut cylinders
Fix: Liftgate struts wear out and latch mechanisms corrode or break linkage rods (subject of multiple recalls). Struts are simple—15 minutes each. Latch assemblies require trim removal and can be fiddly, 1.5-2 hours. Safety issue if latch fails and gate opens in traffic. Always replace struts in pairs.
Estimated cost: $150-400
Front Engine Mount and Transmission Mount Collapse
Common · medium severity
Typical onset: 60,000-110,000 mi
Symptoms: Loud clunk when shifting from Park to Drive or Reverse, Excessive engine rocking during acceleration, Vibration felt through steering wheel and floorboards at idle, Visible sagging or torn rubber on mounts
Fix: Hydraulic engine mounts fail, letting the transverse powertrain rock violently. Transmission mount (right side) collapses first, then dogbone mount. This accelerates CV axle and transmission wear. Front mount requires support beam removal, 2-3 hours. Trans mount is 1.5 hours. Replace all three if one is bad—they age together. Check during every oil change after 60k.
Estimated cost: $350-700
Windshield Wiper Linkage Bushing Wear
Occasional · medium severity
Typical onset: 90,000-150,000 mi
Symptoms: Wipers move erratically or only one blade sweeps, Clicking or popping noise from cowl when wipers run, Wipers park in wrong position or not at all, Driver-side wiper loosens and falls off arm
Fix: Plastic bushings in the wiper linkage wear out, causing misalignment. Motor keeps running but arms don't track properly—dangerous in rain. Linkage is under cowl cover; 1.5-2 hours to remove, replace bushings or full linkage, and reassemble. Aftermarket linkages are cheap but motor failure is also common by this age, so test motor separately before throwing parts at it.
Estimated cost: $200-450
Owner tips
Change transmission fluid every 30,000 miles with Mopar ATF+3 or +4 only—other fluids destroy the A604 solenoids
Inspect transmission cooler lines for rust annually; replace at first sign of corrosion
If buying used, avoid the 3.0L V6 entirely—the 3.3L and 2.4L are far more reliable
Check engine mounts visually every oil change; a $600 mount job beats a $3,000 transmission
Keep detailed maintenance records—these vans have low resale value and any deferred work means scrap
Only buy if under 80,000 miles with documented transmission services and you can verify it's not a 3.0L V6—otherwise, you're gambling on a $3,000+ repair within a year.
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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VEHICLE DESCRIPTION: MINIVANS. THE LEFT HAND WINDSHIELD WIPER PIVOT DRIVE ARM WAS NOT MECHANICALLY STAKED TO THE PIVOT SHAFT.
Consequence: THIS COULD ALLOW THE DRIVE ARM TO DISENGAGE FROM THE SHAFT LEADING TO A LOSS OF WIPER FUNCTION. THE DRIVER'S VISIBILITY WOULD BE IMPAIRED, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE LEFT HAND SIDE WINDSHIELD WIPER PIVOT ASSEMBLY.
SEAT BELTS:FRONT:BUCKLE ASSEMBLY · 97V148000
1997-09-09 · EA96016
VEHICLE DESCRIPTION: PASSENGER MINI-VANS. COVERS ON THE SOLID STALK MOUNTED SEAT BELT BUCKLES CAN BECOME DISLODGED CAUSING THE RELEASE BUTTON TO STICK INSIDE THE COVER. THE BUCKLE WOULD THEN BE ONLY PARTIALLY LATCHED.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL INSTALL A COVER RETAINING CLIP TO THE STALK MOUNTED BUCKLE COVER TO PREVENT DISLOCATION OF THE BUCKLE COVER.
SEAT BELTS:FRONT:ANCHORAGE · 97V149000
1997-09-09 · EA97005
VEHICLE DESCRIPTION: PASSENGER MINI-VANS. THE CENTER REAR SEAT, RIGHT OUTBOARD SIDE, SAFETY BELT ANCHOR HOOK CAN BECOME UNATTACHED FROM THE BODY ANCHOR POSITION.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL REPLACE THE ANCHOR HOOK RETAINING CLIP WITH A REVISED PROFILE CLIP AND A COVER PLATE.
THE BOLTS USED TO ATTACH THE STRUT TO THE BODY AND THE REAR LIFTGATE CAN ACCUMULATE FATIGUE DAMAGE IF THREE FACTORS COMBINE. IF THE BOLT IS LOOSE, THE GAS STRUT IS OVER-PRESSURIZED, AND THE FREQUENCY OF OPENING AND CLOSING CYCLES IS HIGHER THAN FOR THE AVERAGE CUSTOMER, THE BOLT CAN FAIL.
Consequence: PERSONAL INJURY COULD OCCUR IF THE BOLTS BREAK ALLOWING THE LIFTGATE TO FALL SUDDENLY.
Remedy: DEALERS WILL INSPECT FOR LOOSE FASTENERS, IF THE FASTENERS ARE LOOSE, THE STRUT (AND INTEGRAL BOLTS) WILL BE REPLACED. IF THE BOLT SHOWS EVIDENCE OF TORQUE, THE BOLT WILL BE REMOVED, LARGER WASHERS WILL REPLACE THE EXISTING WASHER AND THE BOLT WILL BE REINSTALLED AND HAND TIGHTENED TO THE TARGET TORQUED.
STEERING: STEERING WHEEL/HANDLE BAR · 96V229000
1996-11-18 · RQ00011
THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.
Consequence: IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTROL CAN OCCUR INCREASING THE RISK OF AN ACCIDENT.
Remedy: DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY STEERING WHEELS SHOWING CRACKS WILL BE REPLACED. ALL OTHER VEHICLES WILL HAVE A REINFORCEMENT PLATE INSTALLED TO PREVENT STEERING WHEEL SEPARATION IN THE EVENT CRACKING OCCURS.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP · 96V099000
1996-06-13 · EA95016
THE ABS HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR CAUSING PUMP-MOTOR DETERIORATION.
Consequence: IF THIS CONDITION OCCURS, THE ABS FUNCTION COULD BE LOST AND REDUCED POWER ASSIST WOULD BE EXPERIENCED DURING VEHICLE BRAKING INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL TEST THE VEHICLE'S ANTI-LOCK BRAKE SYSTEM AND REPAIR THE VEHICLES IF NECESSARY. ALSO THE WARRANTY ON ALL ABS COMPONENTS WILL BE EXTENDED TO 10 YEARS OR 100,000 MILES (EXCEPT FOR THE BRAKE ACTUATOR PISTON ASSEMBLY AND THE PUMP-MOTOR ASSEMBLY WHICH WILL HAVE A LIFETIME COVERAGE). OWNERS WILL ALSO BE REIMBURSED FOR PREVIOUS ABS COMPONENT REPAIR COSTS.
VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITHOUT REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.
Consequence: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.
Remedy: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN OCTOBER 1995.
VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITH REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.
Consequence: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.
Remedy: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN MARCH 1996.
FUEL SYSTEM, GASOLINE · 92V147000
1992-10-14
FUEL TANK FLANGES WERE NOT BENT AS REQUIRED TO ALLOW THE SPECIFIED CLEARANCE FOR THE FUEL TANK MOUNTING STRAPS AND FUEL LINES AT THE TANK.
Consequence: THE UNBENT FLANGES TO THE FUEL TANK WILL DAMAGE THEMOUNTING STRAPS AND/OR FUEL LINES. THE DAMAGED MOUNTING STRAPS MAY BREAK CAUSINGTHE TANK TO DROP AND THE DAMAGED FUEL LINE WILL LEAK FUEL. IN EITHER CASE A FIRECOULD RESULT IF THE SPILLED FUEL IS EXPOSED TO AN IGNITION SOURCE.
Remedy: REPAIR THE FLANGE BY BENDING TO THE CORRECT ANGLE; REPLACE DAMAGED FUEL LINES AND MOUNTING STRAPS.
STEERING: STEERING WHEEL/HANDLE BAR · 92V015000
1992-02-14 · PE92004
THE ZINC PLATING OPERATION PERFORMED ON THE UPPER STEERING COLUMN SHAFT COUPLING BOLT CAUSED HYDROGEN EMBRITTLEMENT AND BREAKAGE OF THE BOLT.
Consequence: FRACTURES OF THE UPPER STEERING COLUMN SHAFT COUPLINGBOLT RESULT IN A LACK OF COUPLING LOAD ON THE SHAFT AND LOSS OF STEERINGCONTROL.
Remedy: REPLACE THE ZINC PLATED BOLT WITH A PHOSPHATE PLATED BOLT.
SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES · 91V170000
1991-10-04
THE BRAKE PEDAL PAD ATTACHMENT TO THE PEDAL ARM MAY NOT HAVE ADEQUATE STRENGTH DUE TO MISLOCATION OF WELDS, AND COULD BREAK.
Consequence: FAILURE OF THE PEDAL PAD TO PEDAL ARM ATTACHMENT RESULTSIN LOSS OF BRAKING ABILITY, AND COULD RESULT IN AN ACCIDENT.
Remedy: REPLACE INADEQUATE BRAKE PEDALS WITH PROPERLY MANUFACTURED PEDALS.
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