1991 DODGE SPIRIT

Typical onset: 80,000-130,000 mi

Symptoms: Slipping between gears, especially 2nd to 3rd, Delayed engagement when shifting to Drive or Reverse, Whining or grinding noises during acceleration, Transmission fluid dark or burnt-smelling, Check Engine light with transmission codes

Fix: The three-speed automatic is the Achilles heel. Governor pressure sensor and solenoid pack fail first, but often internal clutches are already worn. Rebuild requires 8-12 hours; many shops recommend replacement with salvage unit (4-6 hours). Oil cooler lines rust through and contaminate fluid—replace cooler and lines during any trans work.

Estimated cost: $1,200-2,800

Typical onset: 90,000-140,000 mi

Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Overheating under load or in traffic, Oil looks milky or chocolate milk-colored, Rough idle and misfires after warming up

Fix: The 2.5L four-cylinder cracks head gaskets between cylinders 2-3 or blows into the cooling jacket. Job takes 10-14 hours because intake manifold and timing components must come off. Always resurface the head (usually warped .003-.008 inches) and replace timing belt, water pump, and all coolant hoses while you're in there. Some techs skip machining—those jobs fail within 15k miles.

Estimated cost: $1,400-2,200

Symptoms: No start, no crank—complete electrical dead spot, Intermittent stalling at idle or when warm, Speedometer and tachometer go haywire, Transmission stuck in second gear (limp mode), Multiple random fault codes stored

Fix: The combined engine/transmission computer (single module on these) sits behind the battery and corrodes from battery acid fumes. Solder joints crack from heat cycles. Replacement takes 1-2 hours but units are scarce—expect salvage yard hunting. Some rebuilders resoldering services exist for $200-350. Must be programmed to VIN, which many indie shops can't do without a DRB-II scan tool.

Estimated cost: $400-900

Typical onset: 70,000-110,000 mi

Symptoms: Heavy clunk when shifting from Park to Drive, Engine rocks excessively during acceleration, Vibration through steering wheel at idle, Thumping noise over bumps from engine bay

Fix: The hydraulic front mount fails and the engine tilts forward, stressing CV axles and exhaust hangers. Right-side mount goes next. Replacement takes 2-3 hours—must support engine from below and remove through wheel well on some configurations. Aftermarket mounts last 30-40k; OEM-spec last 60k if you can find them.

Estimated cost: $250-450

Typical onset: 100,000-150,000 mi

Symptoms: No start with cranking—fuel pump doesn't prime, Stalling after 20-30 minutes of driving when hot, Fuel gauge reads empty when tank is full or stuck on full, Whining noise from rear seat area

Fix: In-tank pump assembly fails from running the tank low repeatedly (pump uses fuel for cooling). Must drop tank (2-3 hours). Sending unit float arms crack. Strongly recommend replacing entire pump module assembly—trying to replace just the pump leads to repeat failures from contaminated sock filter.

Estimated cost: $400-650

Typical onset: 120,000+ mi

Symptoms: AC blows warm, won't hold refrigerant charge, Sweet smell from vents (refrigerant oil), Oily film on inside of windshield, Compressor cycles constantly or not at all

Fix: Evaporator sits behind the dash and corrodes from the inside. This is a 12-18 hour nightmare—entire dash must come out. Most owners live without AC rather than fix it. If you're doing it, replace expansion valve, receiver-drier, and flush the system. R12 systems originally; most are converted to R134a by now but adapters leak.

Estimated cost: $1,200-2,000

Typical onset: 60,000-100,000 mi

Symptoms: Battery light flickers or stays on, Headlights dim at idle, brighten when revving, Battery constantly needs jump-starting, Voltage gauge shows overcharging (16+ volts) or undercharging

Fix: Chrysler alternators of this era have external voltage regulators that fail from heat. Regulator is $30 and takes 20 minutes to swap, but most shops replace the whole alternator (1.5-2 hours) because brushes wear out simultaneously. Remanufactured alternators are hit-or-miss—third failure in a row isn't uncommon.

Estimated cost: $200-400