1991 PLYMOUTH VOYAGER

Typical onset: 60,000-120,000 mi

Symptoms: Delayed engagement into gear, especially reverse, Harsh 2-3 upshift or slipping between gears, No movement in any gear after transmission gets hot, Burnt transmission fluid smell and dark/metallic fluid

Fix: The 4-speed electronic A604/41TE transmission is notorious for solenoid pack failure, governor pressure sensor issues, and clutch pack burnout. Rebuild requires 8-12 hours labor; many shops recommend replacement with a remanufactured unit due to internal wear patterns. External cooler addition is mandatory to prevent repeat failure.

Estimated cost: $1,800-3,200

Typical onset: 80,000-140,000 mi

Symptoms: White smoke from exhaust, especially on cold start, Coolant loss with no visible leaks, sweet smell from exhaust, Oil contamination in coolant or coolant in oil (milky dipstick), Knocking or rod-bearing noise from lower end, especially when warm

Fix: The Mitsubishi 3.0L V6 suffers from thin head gasket material that fails between cylinders or into coolant passages. Once coolant enters oil, main and rod bearings fail rapidly. Head gasket job alone is 10-14 hours; most engines at this mileage need full rebuild or replacement due to bearing damage. Short block replacement is 16-22 hours.

Estimated cost: $2,500-4,800

Typical onset: 70,000-130,000 mi

Symptoms: Red fluid puddles under vehicle, typically near radiator, Transmission overheating and slipping after highway driving, Low transmission fluid level on dipstick with no visible pan leak, Rust stains on radiator support or frame rails where lines pass

Fix: Steel transmission cooler lines rust through where they attach to the radiator or along frame-mounted sections exposed to road salt. Line failure dumps all ATF quickly, destroying transmission if driven. Replacing both lines requires 2-3 hours labor. Often discovered too late after transmission damage has occurred. NHTSA documented this as a recall-level concern.

Estimated cost: $300-600

Typical onset: 60,000-100,000 mi

Symptoms: Heavy clunk when shifting from park to drive or reverse, Excessive engine movement visible from driver's seat on acceleration, Vibration transmitted through steering wheel and shifter, Clicking or knocking from engine bay over bumps

Fix: Hydraulic engine mounts deteriorate and leak fluid, allowing engine to rock excessively. Front mount and transmission mount are typical failures. Both should be replaced together as labor overlaps. Front mount requires 1.5 hours, transmission mount adds another 1.5 hours if done separately, but doing both takes 2.5-3 hours total.

Estimated cost: $350-650

Symptoms: Extended cranking required when engine is hot, especially in summer, Stalling shortly after hot restart, runs fine after cooling, Strong fuel smell under hood after shutting off hot engine, Rough idle or hesitation immediately after hot start

Fix: Fuel system routing near exhaust causes fuel to vaporize in lines and filter housing. Combination of aged fuel pressure regulator, clogged fuel filter, and heat-soaked injectors compounds the issue. Fuel filter replacement (0.8 hours) and fuel pressure regulator (1.5 hours) typically resolves it. Heat shielding addition helps long-term.

Estimated cost: $250-450

Typical onset: 80,000-150,000 mi

Symptoms: Door will not latch closed, bounces open while driving, Interior door ajar light stays on with door visibly closed, Door sags and requires lifting to close properly, Grinding or binding when opening/closing sliding door

Fix: Latch mechanism wears and plastic components break internally. Door hinge rollers crack and bind on track. Latch replacement is 1-2 hours; hinge roller set adds another 2 hours. NHTSA issued multiple recalls for latch failures. If hinges are severely worn, door alignment becomes permanent issue.

Estimated cost: $200-550

Symptoms: Visible rust holes in front inner fender wells near strut towers, Crunching sound when turning wheel at full lock, Alignment will not hold specifications, pulls after potholes, Front strut visibly loose or leaning in engine bay

Fix: Salt-belt vehicles experience rust-through on unibody strut tower mounts and front subframe attachment points. Once structural rust begins, repair requires welding new metal, which is rarely economical. This is a totaling condition on older examples. Inspection during any suspension work is critical. Not a fixable wear item—vehicle becomes unsafe to drive.

Estimated cost: Not repairable economically