The 2000 Plymouth Voyager is the tail end of the third-generation Chrysler minivan platform, notorious for catastrophic automatic transmission failures and 2.4L engine bottom-end problems. Budget heavily for drivetrain repairs or walk away.
Automatic Transmission Failure (41TE/31TH)
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Harsh or delayed 2-3 shift, transmission 'bumping' into gear, Slipping on acceleration, especially when warm, No movement in any gear after warning signs ignored, Burnt transmission fluid smell, dark red or brown fluid
Fix: These 4-speed automatics have weak overdrive clutch packs and solenoid pack failures. Rebuild runs 12-16 hours labor plus parts; remanufactured unit swap is 8-10 hours. Transmission cooler lines often corrode and leak into the cooler itself—always replace cooler, lines, and flush the system during rebuild or you'll be back in six months.
Estimated cost: $2,200-3,800
2.4L Engine Bottom-End Failure
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: Rod knock on cold start that worsens as engine warms, Sudden loss of oil pressure, oil light flickering at idle, Metallic rattling from lower engine block, Catastrophic failure: thrown rod through block
Fix: The 2.4L DOHC has inadequate oil delivery to rod bearings, especially cylinders 2 and 3. Sludge buildup accelerates failure. Once knocking starts, you need a complete short-block or used engine replacement—18-24 hours labor. Pistons, rings, crank, and bearings all need attention; head gasket replacement is mandatory during teardown. This is often a total-loss scenario for the vehicle.
Estimated cost: $3,500-5,500
Intake Manifold Gasket Failure (3.3L V6)
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust on cold start, Rough idle, misfire codes (especially P0300-P0306), Coolant in oil (milky dipstick) in severe cases
Fix: The plastic intake plenum gasket deteriorates and allows coolant into cylinders. Requires upper intake removal, gasket set, and often new plenum if warped—6-8 hours labor. Check for coolant contamination in oil; if present, budget for oil/filter changes every 500 miles for three cycles post-repair to flush the system. The 3.0L Mitsubishi V6 doesn't have this issue.
Estimated cost: $650-1,100
Front Engine Mount Collapse
Occasional · medium severity
Typical onset: 80,000-140,000 mi
Symptoms: Severe clunk or thud when shifting from Park to Drive/Reverse, Excessive engine rocking visible from driver's seat during acceleration, Vibration through steering wheel and floor at idle, Hood appears misaligned or higher on one side
Fix: The hydraulic front mount (dogbone) fails, allowing the engine to torque violently and stress other mounts and the transmission mount. Front mount replacement is 2-3 hours; always inspect and often replace the right-side mount simultaneously—it carries the load once the front fails. Transmission mount failure follows within 6-12 months if not addressed together.
Estimated cost: $350-600
Power Sliding Door Cable Failure
Occasional · low severity
Typical onset: 90,000-150,000 mi
Symptoms: Door opens or closes halfway then stops, beeping error, Manual operation difficult, feels like it's binding, Cable visible hanging loose behind door trim, Door stuck in partially open position
Fix: Drive cables fray and snap at pulleys. Requires door trim removal, cable routing through tracks, and motor/module recalibration—4-6 hours labor per door. Aftermarket cables are available but OE Mopar cables last longer. Many owners disable the power function and operate manually to avoid the $800 repair bill.
Estimated cost: $700-1,200
ABS Pump Module Failure
Occasional · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: ABS and brake warning lights illuminated together, Grinding or chattering from ABS pump on startup, Loss of ABS function, conventional brakes still work, Pump runs continuously, draining battery overnight
Fix: The ABS pump motor and controller corrode internally. Replacement requires brake system bleeding and recalibration—3-4 hours labor. Remanufactured units are the only cost-effective option; new OE is $1,200+ for the part alone. System must be bled with a scan tool to clear codes and reactivate ABS functionality.
Estimated cost: $800-1,400
Fuel Pump Failure
Occasional · high severity
Typical onset: 110,000-180,000 mi
Symptoms: No-start condition, crank but no fire, Stalling at operating temperature, especially in hot weather, Whining or buzzing noise from rear of vehicle, Intermittent stalling that becomes more frequent over weeks
Fix: In-tank pump fails from wear and contamination. Requires fuel tank drop, pump module replacement, and strainer—3-4 hours labor. Related recall (00V229000) addressed some early failures but didn't cover all units. Always replace the fuel filter during this job (it's often the root cause of pump failure from restriction). Test fuel pressure before condemning the pump—regulator failures mimic pump symptoms.
Estimated cost: $550-850
Owner tips
Change transmission fluid every 30,000 miles with ATF+4 only—this buys time but won't prevent eventual failure on high-mileage units
If buying a 2.4L model, verify strict 3,000-mile oil change history; even slight sludge is a walk-away sign
The 3.0L Mitsubishi V6 is the most reliable engine option but underpowered for highway merging with a loaded van
Replace all three engine/transmission mounts as a set once one fails—labor overlap saves money and prevents cascading damage
Budget $1,000-1,500 annually for unexpected repairs after 100,000 miles; this platform nickel-and-dimes you to death
Only buy if under $2,000, you can wrench yourself, and you need cheap temporary transportation—otherwise the transmission or 2.4L engine will cost more than the van's worth 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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CURT MFG IS RECALLING CERTAIN CLASS 3 RECEIVER HITCHES, P/N 13347, SOLD AS AFTERMARKET EQUIPMENT FOR USE ON 1997-2007 CHRYSLER TOWN AND COUNTRY VANS, 1996-2007 DODGE CARAVANS, AND 1996-2004 PLYMOUTH VOYAGER VANS. WHEN THE HITCH IS LOADED TO THE MAXIMUM RATING, THE HITCH MAY FRACTURE OR BREAK AT THE BEND LOCATION WHERE THE MAIN BODY OF THE HITCH MEETS THE HITCH MUFFLER STRAP.
Consequence: IF THE AREA IN QUESTION FRACTURES OR BREAKS, THIS COULD CAUSE AN UNSTABLE DRIVING CONDITION, POSSIBLY RESULTING IN A CRASH.
Remedy: CURT MFG WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE THE HITCH FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING AUGUST 2010. OWNERS MAY CONTACT CURT MFG AT 1-715-831-8713.
VISIBILITY:GLASS, SIDE/REAR · 07E104000
2007-12-11
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
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.
SERVICE BRAKES, HYDRAULIC · 06E022000
2006-03-13
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Consequence: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
AIR BAGS · 04V480000
2004-10-06 · EA04013
ON CERTAIN MINIVANS, THE DRIVER'S AIR BAG MAY BECOME DISABLED DUE TO A FAILURE OF THE CLOCKSPRING, WHICH IS LOCATED IN THE HUB OF THE STEERING WHEEL.
Consequence: THIS CONDITION WILL MANIFEST ITSELF THROUGH ILLUMINATION OF THE AIR BAG WARNING LAMP, AND COULD EVENTUALLY RESULT IN A DRIVER'S AIR BAG OPEN CIRCUIT, IF THE PART IS NOT REPLACED IN A REASONABLE AMOUNT OF TIME.
Remedy: DEALERS WILL REPLACE THE CLOCKSPRING ASSEMBLY ON ALL COVERED VEHICLES WITH 70,000 MILES OR LESS. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DAIMLERCHRYSLER WILL OFFER AN EXTENDED LIFETIME WARRANTY UNDER WHICH IT WILL REPLACE THE CLOCKSPRING AT NO CHARGE IF IT FAILS. DAIMLERCHRYSLER WILL ALSO REIMBURSE OWNERS WHO HAVE PAID TO HAVE THE CLOCKSPRING REPLACED ON THEIR VEHICLES. THE RECALL BEGAN ON OCTOBER 12, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
FUEL SYSTEM, GASOLINE · 03E053000
2003-10-24
CERTAIN AFTERMARKET REPLACEMENT FUEL FILTERS, MODELS WIX FILTER PART NUMBERS 33576, 33577, 33734; NAPA FILTER PART NUMBERS 3576, 3577, 3734; AND CARQUEST FILTER PART NUMBERS 86576, 86577, 86734 USED ON 1996-2000 DAIMLERCHRYSLER TOWN & COUNTRY, DODGE CARAVAN, AND PLYMOUTH VOYAGER VEHICLES, CAN CAUSE THE FUEL LINES TO LEAK.
Consequence: A POSSIBLE FIRE CAN OCCUR IN THE PRESENCE OF AN IGNITION SOURCE.
Remedy: WIX WILL NOTIFY ITS CUSTOMERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE.
NOTE: THIS DOES NOT INVOLVE ANY PRODUCTS MANUFACTURED BY THE DAIMLERCHRYSLER CORP. NOR ANY DAILMERCHRYSLER DEALERS.
OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING NOVEMBER 2003. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT WIX AT 704-864-6711.
EQUIPMENT · 03E045000
2003-09-26
AFTERMARKET REPLACEMENT FUEL FILTERS MANUFACTURED BETWEEN SEPTEMBER 17, 2002, AND JANUARY 20, 2003, SOLD UNDER THE BRAND NAMES LISTED ABOVE. THE FILTER MAY EXPERIENCE MALFUNCTION OF THE QUICK CONNECTOR EITHER BLOCKING FUEL FLOW TO THE ENGINE OR CAUSING A FUEL LEAK. THIS DOES NOT INVOLVE ANY PRODUCTS MANUFACTURED BY THE DAIMLERCHRYSLER CORP. NOR ANY DAILMERCHRYSLER DEALERS.
Consequence: IF THIS CONDITION OCCURRED WHILE THE VEHICLE IS IN MOTION, THE ENGINE COULD STALL. ALSO, IN THE PRESENCE OF AN IGNITION SOURCE, THE FUEL LEAK COULD RESULT IN A VEHICLE FIRE.
Remedy: AFTERMARKET REPLACEMENT FUEL FILTERS FOR 1995-2000 SHORT WHEELBASE CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 18232 AND DATE CODE 0237, 0249, OR 0252.
REPLACEMENT FUEL FILTERS FOR 1995-2000 LONG WHEELBASE CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 18230 AND DATE CODE 0237, 0249, 0251, OR 0304.
REPLACEMENT FUEL FILTERS FOR 2001-2004 CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 28871 AND DATE CODE 0249. THESE PART NUMBERS AND DATE CODES APPEAR ON THE GOLD-TONE FILTER.
DISTRIBUTORS AND RETAILERS WILL BE NOTIFIED TO ISOLATE AND RETURN AFFECTED INVENTORY. OWNERS WHO HAVE HAD THE FUEL FILTER SERVICED ON ONE OF THE APPLICABLE VEHICLES AFTER SEPTEMBER 17, 2002 SHOULD RETURN THEIR VEHICLE TO THE SERVICE FACILITY TO BE INSPECTED TO SEE IF THE FUEL FILTER THAT WAS INSTALLED IS ONE THAT IS INVOLVED IN THE RECALL. IF SO, THE OWNERS SHOULD HAVE THE FILTER REPLACED. TO RECEIVE A FULL REFUND PLUS THE COST OF POSTAGE, OWNERS SHOULD CUT THE CONNECTORS FROM THE HOSES, RINSE THE CONNECTORS AND RETURN THEM TOGETHER WITH PROOF OF THE AMOUNT PAID FOR THE REPLACEMENT PART AND LABOR, TO INTERCONTINENTAL AT INTERCONTINENTAL AUTO PARTS, INC., P.O. BOX 861, MAHWAH, NJ 07430, ATTN: FUEL FILTER RECALL. INTERCONTINENTAL WILL MAIL A FULL REFUND TO THE OWNER.
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM · 00V268000
2000-09-13 · RQ00008
VEHICLE DESCRIPTION: MINI VANS BUILT WITH 3.3L AND 3.8L ENGINES HAVE FUEL RAILS WITH NITROLE RUBBER O-RING SEALS THAT CAN DEGRADE OVER TIME. FUEL LEAKAGE FROM THE UNDERHOOD FUEL INJECTION FUEL RAIL COULD RESULT, INCREASING THE LIKELIHOOD OF A VEHICLE FIRE.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: DEALERS WILL INSTALL A SEAL ON THE VEHICLE FUEL RAILS TO PREVENT EXTERNAL LEAKAGE OF FUEL FROM THE FUEL RAIL CROSSOVER TUBE, SHOULD THE EXISTING O-RINGS CONTINUE TO DEGRADE. OWNER NOTIFICATION BEGAN ON JANUARY 25, 2002. DUE TO THE LARGE QUANTITY OF VEHICLES INVOLVED IN THIS CAMPAIGN, THE OWNER NOTIFICATION WILL BE PHASED OVER THE NEXT SEVERAL MONTHS. HOWEVER, IF A VEHICLE IS LEAKING FUEL FROM THE O-RINGS, THE VEHICLE SHOULD BE TAKEN INTO A DEALER TO HAVE THIS REPAIRED AS SOON AS POSSIBLE. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
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