1994 PLYMOUTH VOYAGER

Typical onset: 80,000-140,000 mi

Symptoms: Harsh shifting or slipping between gears, especially 2nd to 3rd, No movement in Drive or Reverse after warm-up, Whining or grinding noises from transmission, Check Engine Light with transmission codes (P0700 series if scanner available)

Fix: The A604/41TE is legendary for solenoid pack failures, clutch pack burnout, and valve body issues. Rebuild requires 8-12 hours labor; many shops recommend replacement with remanufactured unit due to internal wear patterns. External cooler flush and new trans mount mandatory during service.

Estimated cost: $2,200-3,800

Typical onset: 90,000-150,000 mi

Symptoms: White smoke from exhaust on startup, Coolant disappearing with no visible leaks, Overheating especially under load or hot weather, Oil turned milky brown or coolant has oil film, Rough idle or misfire after engine warms up

Fix: The 3.0L Mitsubishi V6 has poor head bolt design and weak head gasket material. Both heads must be removed, checked for warpage (machining adds $150-250), and MLS gaskets installed with upgraded bolt torque procedure. Book time 10-14 hours. Timing belt replacement mandatory while heads are off. If coolant contaminated oil and owner kept driving, expect rod bearing or crank damage requiring full rebuild.

Estimated cost: $1,800-2,500

Symptoms: Liftgate won't stay open or drops suddenly (hinge failure), Latch won't engage or release, door won't close securely, Rust visible around hinge mounting points on body, Door rattles or has excessive play when closed

Fix: Both hinges and latches are prone to fatigue cracking and corrosion. NHTSA recalled liftgate hinges and latches multiple times but many weren't fixed. Hinge replacement requires 2-3 hours per side and often uncovers hidden rust requiring panel repair. Latch mechanism replacement is 1.5 hours but aftermarket parts fail quickly.

Estimated cost: $300-800

Typical onset: 100,000-180,000 mi

Symptoms: Excessive oil consumption (1 qt per 500-1000 miles), Blue smoke on deceleration or startup, Loss of power and sluggish acceleration, Spark plugs oil-fouled at inspection, Low compression on multiple cylinders

Fix: The 2.4L DOHC had marginal piston ring design and oil control issues. Once oil consumption starts, it accelerates quickly. Requires engine removal, full teardown, re-ring or replacement pistons, hone cylinders, new bearings. 18-24 hours labor. Many shops recommend short block replacement or used engine swap instead of rebuild due to parts cost.

Estimated cost: $2,800-4,500

Typical onset: 70,000-120,000 mi

Symptoms: Transmission fluid dripping under vehicle near radiator, Pink or red fluid visible on driveway, Transmission overheating or burnt smell, Low transmission fluid on dipstick despite no visible drips (internal cooler leak into coolant)

Fix: Steel cooler lines rot out where they mount to radiator, especially in salt states. External line replacement is 1.5-2 hours. If internal cooler failed (coolant/trans fluid mixing), radiator replacement mandatory plus complete transmission flush and filter, 3-4 hours total. Internal contamination often kills transmission within 5,000 miles.

Estimated cost: $250-450 (lines only), $600-1,200 (with radiator and flush)

Symptoms: Clunking felt through steering wheel when turning, Steering wheel has excessive play or feels disconnected, Difficulty turning at low speeds, Visible gap or movement in steering shaft under dash

Fix: The rubber flex coupler connecting upper and lower steering shafts deteriorates and separates. NHTSA recall issued but many never repaired. Replacement requires 2-3 hours with dash trim removal. Aftermarket parts available but factory coupler is recommended for safety-critical component.

Estimated cost: $250-450