The 1997 Plymouth Grand Voyager represents Chrysler's third-generation minivan with the notorious 41TE/A604 four-speed automatic transmission — the single biggest reliability concern on this platform. The 3.3L and 3.8L V6 engines are generally durable but prone to head gasket failures and intake plenum gasket leaks when neglected.
41TE/A604 Automatic Transmission Failure
Common · high severityTypical onset: 80,000-140,000 mi
Symptoms: Harsh or delayed shifts between gears, especially 2-3 upshift, Transmission slipping under load or refusing to engage, Limp mode with check engine light, trans stuck in second gear, Whining or grinding noise from bellhousing area
Fix: The 41TE is infamous for solenoid pack failures, valve body issues, and output shaft bearing failures. Fluid changes every 30k help but don't prevent it. Most need full rebuild or replacement. Rebuild takes 8-12 hours labor; remanufactured unit swap is 6-8 hours.
Estimated cost: $2,200-3,800
Head Gasket Failure (Both Banks)
Occasional · high severityTypical onset: 120,000-180,000 mi
Symptoms: White smoke from exhaust, especially on cold start, Coolant loss with no visible leaks, sweet smell from tailpipe, Oil contamination in coolant reservoir or milky dipstick, Overheating or rough idle with misfires
Fix: Both 3.3L and 3.8L are prone to head gasket weepage, especially if overheated once. Requires heads pulled, resurfaced, and new gaskets. Factor valve job while heads are off. 12-16 hours labor for both banks.
Estimated cost: $1,800-2,800
Intake Plenum Gasket Leak
Common · medium severityTypical onset: 90,000-150,000 mi
Symptoms: Rough idle and hesitation on acceleration, Vacuum leak codes (P0171, P0174 lean codes), Whistling or hissing sound from upper engine area, Oil seepage visible on lower intake plenum
Fix: The lower intake plenum gasket deteriorates and causes vacuum leaks and oil seepage into intake runners. Upper plenum must come off to access. Use updated Mopar gasket set, not cheap aftermarket. 3-4 hours labor.
Estimated cost: $450-750
Transmission Oil Cooler Line Corrosion/Leaks
Common · high severityTypical onset: 100,000+ mi
Symptoms: Red ATF fluid pooling under vehicle near radiator area, Transmission fluid level dropping rapidly, Transmission overheating and slipping after fluid loss, Visible rust perforation on steel cooler lines
Fix: Steel transmission cooler lines rust through where they route near subframe, especially in salt states. Loss of fluid kills the already-fragile 41TE within miles. Replace both lines preventively. 2-3 hours labor plus flush and refill.
Estimated cost: $350-600
Engine Mount and Transmission Mount Failure
Common · medium severityTypical onset: 80,000-120,000 mi
Symptoms: Excessive engine vibration at idle, especially in gear, Clunking when shifting from park to drive or reverse, Steering wheel shakes at idle with AC on, Visible sagging or torn rubber on motor mounts
Fix: Hydraulic engine mounts and the front transmission mount collapse. Right-side engine mount is especially problematic. Replace all three (left, right, trans) as a set. 2-3 hours labor total.
Estimated cost: $400-700
Front Suspension Ball Joint and Tie Rod Wear
Occasional · high severityTypical onset: 90,000-140,000 mi
Symptoms: Clunking noise over bumps from front end, Wandering or loose steering feel, Uneven tire wear on inside or outside edges, Play in wheel when jacked up and rocked top-to-bottom
Fix: Lower ball joints and outer tie rod ends wear, especially on higher-mileage vans. Ball joints require control arm replacement (not serviceable separately). Inner and outer tie rods often need replacement together. 4-5 hours for full front-end refresh with alignment.
Estimated cost: $800-1,400
Blower Motor Resistor and Switch Failure
Common · low severitySymptoms: Blower only works on high speed setting, No blower function on any speed, Intermittent blower operation, Burning smell from HVAC controls
Fix: The blower motor resistor block under the dash fails frequently, sometimes taking the switch with it. Resistor is 0.5 hours; if switch also failed add another hour. Check blower motor amp draw before replacing parts.
Estimated cost: $150-350
Buy only if transmission has been recently rebuilt with receipts and you can wrench yourself — the 41TE will fail, it's just a question of when, and repair costs exceed the van's value.
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.