1992 PLYMOUTH GRAND VOYAGER

Typical onset: 80,000-140,000 mi

Symptoms: Harsh shifting or slipping between gears, No movement in any gear (forward or reverse), Transmission fluid burnt smell or dark appearance, Delayed engagement when shifting to Drive

Fix: The A604 four-speed automatic is notoriously weak in these vans. Governor pressure sensor and solenoid pack failures lead to complete transmission death. Rebuild requires 8-12 hours; most shops recommend replacement with remanufactured unit due to internal clutch pack and valve body design flaws. External oil cooler lines also corrode and leak, starving transmission of fluid.

Estimated cost: $1,800-3,200

Typical onset: 100,000-150,000 mi

Symptoms: White smoke from exhaust (coolant burning), Overheating with no external leaks, Milky oil on dipstick, Coolant loss with no visible puddles, Knocking or bearing noise from crankcase

Fix: The 3.3L develops head gasket leaks between cylinders and coolant jackets, often progressing to warped heads. Worse, these engines suffer piston ring failure and spun rod bearings due to inadequate oiling and piston skirt design. Head gasket job alone is 10-14 hours; full rebuild or short block replacement runs 18-28 hours. Many owners discover multiple internal failures simultaneously.

Estimated cost: $2,500-5,500

Typical onset: 70,000-110,000 mi

Symptoms: Severe clunking when shifting into gear, Vibration at idle that disappears under load, Visible engine/trans movement when accelerating, Difficulty shifting (manual feel affected)

Fix: The front transmission mount fatigues and separates, allowing excessive drivetrain movement. This cascades into CV joint damage and worsens transmission stress. Replacement is 2-3 hours but requires supporting the engine and trans properly. Inspect all three mounts simultaneously; rubber deteriorates quickly on these vans.

Estimated cost: $250-450

Symptoms: Liftgate drops suddenly when opened, Will not stay open without prop, Latch won't catch or release properly, Hatch rattles while driving

Fix: Gas struts lose pressure and liftgate latches bind or break (subject to multiple recalls). Struts are 0.5 hours per pair; latch mechanism is 1-2 hours depending on corrosion. These failures are universal on surviving examples due to age and repeated cycling. Latch linkage rods corrode in northeastern climates.

Estimated cost: $150-400

Symptoms: Wipers move erratically or not at all, One wiper works, other doesn't, Clicking noise from wiper motor area, Wipers park in wrong position

Fix: Plastic pivot bushings in the wiper linkage under the cowl turn to dust. Linkage arms separate and bind. Repair requires cowl removal and linkage rebuild or replacement, 2-3 hours labor. This is safety-critical in rain; was subject to NHTSA recall but bushings continue failing on aged vehicles.

Estimated cost: $300-550

Symptoms: Seat belt won't latch or releases spontaneously, Visible cracks around belt anchor points, Belt hangs loose with no tension, Buckle mechanism jams or won't release

Fix: Recalled multiple times for front seat belt anchors pulling through floor pan and buckle mechanisms failing to latch properly. Inspect floor pan for rust perforation around anchor bolts. Buckle replacement is 0.5-1 hour per seat; anchor reinforcement requires 2-4 hours and welding in severe cases. Critical safety item.

Estimated cost: $200-800

Typical onset: 90,000-140,000 mi

Symptoms: ABS light illuminated constantly, Brake pedal pulsation during normal stops, Loss of power assist feel, Grinding noise from ABS pump area

Fix: Early Bendix 10 ABS systems have pump motor failures and controller corrosion issues. Diagnosis requires scan tool; many techs disable the system rather than repair due to parts scarcity. Functional repair with used components is 3-5 hours. Brake function remains but without ABS modulation.

Estimated cost: $600-1,200