1991 Plymouth Grand Voyager Problems

What owners report

Owners of this model year most often describe brake trouble, especially with the ABS system: the brake and ABS lights come on, the pedal feels stiff or travels too far, and stopping distances grow. Many complaints note that recall 96V099000 work had been done but the symptoms returned, and it tied several owners up with dealers over parts and warranty. Fuel leaks from the fuel rail and seat belt anchorage failures are the other recurring themes.

1. 1
   Brakes

   ABS and brake assist loss (hard pedal, long stopping)

   • 35 complaints (21%)
   • median 75,000 mi at 16.0 yrs old (8 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1996–2018

   Complaints describe the ABS and brake lights coming on while driving and the pedal becoming hard or sinking toward the floor, with the van taking much longer to stop or not stopping at all in some accounts. Owners say they were told the repair under recall 96V099000 had been performed or that the system could not be duplicated as faulty, yet the same symptoms came back, sometimes more than once. Several report that parts for the ABS hydraulic assembly and pump motor were no longer available or that the recall work was declined, and that the manufacturer would not assist further. Reported from roughly 30,000 to over 220,000 miles, with many accounts in normal driving at highway and around-town speeds.

   Recall 96V099000

   What to check: Ask whether the ABS recall work was completed and whether the hydraulic control unit or pump motor has been replaced since; have a shop check brake assist and pedal feel, and confirm ABS and brake lights behave normally on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Recall 96v099000 concerning ABS brake failure. Dealer claimed to have fixed the recall work on the ABS system. But brakes still experienced the same problems as before. Brakes experienced extended stopping distance.”

   NHTSA complaint #10053823, filed 2004-01, 10,000 miles

   “Abs light came on while driving. Vehicle was locking up and jerking when consumer applied brakes for a normal stop at about 45-50 MPH/no braking action, pedal felt hard. Consumer hit fence to get vehicle to stop. Damage was $ 2000. Consumer did not have time to apply brakes again, was concerned about hitting another vehicle. Please add additional information.”

   NHTSA complaint #889945, filed 2001-06
2. 2
   Fuel system

   Fuel smell and leaks from the fuel rail

   • 12 complaints (7%)
   • median 140,000 mi at 14.4 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1999–2011

   Owners describe smelling gasoline inside the van or through the vents while driving, then finding fuel dripping or spraying from the fuel rail or injector area onto the engine. Complaints mention puddles of fuel on top of the engine, continuous leaks while parked, and mechanics reporting leaking rail or injector seals. Repair often involved replacing the rail or seals, and some owners say the part had to come from a dealer and was expensive or back-ordered. Mostly reported between about 79,000 and 155,000 miles, often noticed during driving or shortly after servicing.

   What to check: Look and smell around the fuel rail and injectors when the engine is cold, check for damp spots or fuel odor in the engine bay, and ask whether the fuel rail or injector seals have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “My 1991 Plymouth Grand Voyager has had so many problems. I have had to replace the whole exhaust system, the transmission, put in a new fuel pump, a new radiator, now it failed an emissions test and I was smelling fuel when I was driving only to find out my fuel rail is leaking or should I say squirting as onto the engine, which almost resulted in a fire had I had been smart enough to check it out. …”

   NHTSA complaint #10140727, filed 2005-10

   “While traveling on the highway and without prior warning fuel smell was coming though the vents. Independent mechanic found that fuel rail was leaking gasoline.”

   NHTSA complaint #10051846, filed 2003-12, 140,000 miles
3. 3
   Transmission and drivetrain

   Transmission dropping out of gear or failing

   • 20 complaints (12%)
   • typically at 8.8 yrs old
   • filed 1997–2005

   Owners report the transmission suddenly going into neutral or quitting while driving at highway speed, sometimes with grinding noises beforehand, leaving the van coasting. In several accounts the transmission had to be replaced, and one owner said the dealer attributed it to internal wear. Some also describe related drivetrain trouble such as a front axle breaking at low speed. Reported at varied mileages, including a repeat failure around 100,000 to 140,000 miles.

   What to check: Check transmission fluid condition, ask for service or rebuild records, and test drive at highway speed watching for delayed or harsh shifting and any grinding.

   2 excerpts from owner complaints in NHTSA records

   “While driving down the freeway we heard a noise and the transmission went into neutral. We had to pull over shut off the vehicle and restart. Since we have found it needs a new transmission.”

   NHTSA complaint #754270, filed 2001-11

   “Vehicle been experiencing reoccurring problem with transmission; fist repairs done at 100,000 mile; currently problem reappeared at 140.000. Believed this condition is due to manufacturer's. Defects. Can NHTSA help or provide additional information.”

   NHTSA complaint #850275, filed 1999-10
4. 4
   Seat belts

   Seat belt anchorage and buckle problems

   • 30 complaints (18%)
   • typically at 5.8 yrs old
   • 1 mention a crash, fire or injury
   • filed 1996–2001

   Complaints describe the seat belt hook on the middle-row right side coming unhooked from the floor anchor, sometimes repeatedly, so the belt no longer holds. Some owners also report the release button sticking or the buckle being only partly latched. Several say they had not yet had the dealer inspect it, and the recurring unhooking was described as happening simply while putting the belt on. Reported on vans from the early 1990s onward with no clear mileage pattern in the sample.

   Recall 97V148000Recall 97V149000

   What to check: Ask whether the seat belt buckle and rear anchorage recalls were completed, then pull each belt firmly at its anchor points and check that buckles latch and release cleanly.

   2 excerpts from owner complaints in NHTSA records

   “The seat belt hook on the right side in the middle of the vehicle disengages from the metal floor anchor. The spring clip is broken, causing the seat belt to be inoperable. Consumer has not taken vehicle to the dealer. Please give further information.”

   NHTSA complaint #811805, filed 1997-04

   “Ea-97-005, safety belt anchorage failure. The safety belt anchorage releases frequently when belt is in use. Vehicle was purchased in may of 91. The spring clip is not broken. Dealer has not looked at problem.”

   NHTSA complaint #811899, filed 1997-05
5. 5
   Body and structure

   Rear liftgate struts and sliding door problems

   • 18 complaints (11%)
   • median 50,847 mi at 16.0 yrs old (1 states mileage, few)
   • filed 1996–2008

   Complaints describe the rear liftgate strut bolts and brackets failing so the tailgate no longer stays open, and in one account the strut broke loose and shot through the headliner. Owners also report the sliding door jumping its track and hanging off the van, with dealers unable to identify the cause. Some say recall 99V213000 work was refused or that the area stayed noisy afterward. Reported across a range of ages and mileages, including after recall repairs had been made.

   Recall 99V213000

   What to check: Open and close the liftgate and sliding door several times, check that the gate holds itself open and the door tracks smoothly, and ask whether the liftgate strut recall was performed.

   2 excerpts from owner complaints in NHTSA records

   “Recall 99 v 213 000/liftgate support bracket redlands auto center, redlands, ca; phone 909/793-2141 refused to honor recall because title indiicated it was a salvage vehicle. Seeking help from NHTSA in this matter.”

   NHTSA complaint #882808, filed 2001-03

   “While driving vehicle the rear hatch came open, owner received a recall notice for the problem, had work corrected, but is still concerned for his safety because he knows that hatch area is still noisy.”

   NHTSA complaint #810119, filed 1997-04

Buying note. On a van this old, service history matters more than anything: confirm which recalls were done and whether brake and fuel-system parts have been replaced, and budget for a pre-purchase inspection that covers the ABS, fuel rail, seat belt anchors and transmission.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.