1991 Plymouth Voyager Problems

What owners report

Owners of this model year most often describe brake problems, especially with the anti-lock system: warning lights, hard or spongy pedals and reduced stopping power, reported from low mileage up into the 100,000s. Second to that are seat belt latch and anchorage failures and body issues such as liftgate strut bolts and door welds or sliding door tracks letting go. Transmission and engine-related complaints (fuel leaks at the injector rail, oil pan leaks) round out the sample, with most reports arriving on vehicles well past 70,000 miles.

1. 1
   Brakes

   ABS warning light and loss of brake pedal

   • 151 complaints (29%)
   • median 123,203 mi at 14.4 yrs old (6 state mileage, few)
   • 6 mention a crash, fire or injury
   • filed 1995–2010

   Complaints describe the ABS or brake warning lights coming on while driving, sometimes followed by a pedal that goes to the floor and must be pumped to stop. Owners report hard pedals, long stopping distances and, in some cases, the pump running and draining the battery while parked. Dealers replaced the ABS pump, accumulator pressure switch or master cylinder; several owners say the problem returned after repair or could not be duplicated by the dealer. Reports span roughly 46,000 to 185,000 miles, with many in the 73,000-138,000 mile range.

   Recall 96V099000Recall 92V030000Recall 91V191000

   What to check: Ask for service records on ABS repairs, and check whether recall 96V099000 was performed and whether any follow-up repair was needed. Watch for warning lights on a test drive and test pedal feel at low speed.

   2 excerpts from owner complaints in NHTSA records

   “Brakes failed to stop and light comes on w/anti lock light chrysler replaced with another exact part from junkyard and charged me for new parts $937.59. 1.5 yrs. Later same problem occurs, this is how I learned what they had done.”

   NHTSA complaint #10070732, filed 2004-01, 138,406 miles

   “Brake failure 1991 Plymouth van ABS system failure pumps brake fluid out top fill caps while parked & runs battery down to dead also hard pedal at any time fails to stop ABS system was repaired or replaced about 1999 dash warning go on & off at any time been dealer shop 4 weeks dispute lifetime warranty for recall.”

   NHTSA complaint #10236467, filed 2008-07, 179,000 miles
2. 2
   Body and structure

   Liftgate strut bolt and door/door-weld failures

   • 81 complaints (16%)
   • median 164,408 mi at 16.7 yrs old (2 state mileage, few)
   • 5 mention a crash, fire or injury
   • filed 1995–2010

   Complaints describe the bolts holding the rear liftgate gas struts breaking, letting the hatch drop suddenly or the strut rod push into the headliner. Owners also report sliding doors coming off their tracks and door welds separating so that doors jam or hang loose. Dealers in some cases refused the liftgate strut repair because the recall campaign was old. Spread from the late 1990s into 2010, generally on vehicles past 100,000 miles.

   Recall 99V213000

   What to check: Open and close the liftgate repeatedly and inspect the strut mounting bolts for looseness, then operate the sliding door through its full travel. Ask whether recall 99V213000 was completed.

   2 excerpts from owner complaints in NHTSA records

   “Left rear hatch strong arm which lifts the hatchback exploded, shearing cylinder rod chassis connecting stud, permitting cylinder rod to force its way under plastic finish trim/headliner into pasenger compartment, almost striking rear seat occupant.”

   NHTSA complaint #815211, filed 1997-09

   “Vehicle experiencing problem with sliding door keeps coming off. Door been repaired on three occasions, but door still keeps coming off.this can lead to someone being thrown out of vehicle if invoved in a collision.”

   NHTSA complaint #854383, filed 1999-12
3. 3
   Seat belts

   Seat belt buckle and anchorage failures

   • 105 complaints (20%)
   • median 157,000 mi at 12.1 yrs old (1 states mileage, few)
   • 7 mention a crash, fire or injury
   • filed 1995–2003

   Owners describe rear center seat belt anchors and latch clips breaking or releasing while the belt is in use, and front buckles that jam or only partly latch. Several complaints reference recall campaigns for the front buckles and rear anchorage and note difficulty getting the parts or the repair done, including vehicles far from a dealer. Mostly reported on older vehicles, from the mid-1990s onward with high mileage; several complaints give no mileage.

   Recall 97V148000Recall 97V149000

   What to check: Pull each belt fully and latch and release it several times, including the rear center seat, and ask whether recalls 97V148000 and 97V149000 were completed.

   2 excerpts from owner complaints in NHTSA records

   “The driver's seat belt does not lock in the buckle. Once inserted the metal piece into the release part the belt jams, causing the driver not to be able to get out prior to recall (97v-148).”

   NHTSA complaint #820874, filed 1998-02

   “In reference to ea97-005, the vehicle rear center seat/right side seat belt anchorage releases when the belt is in use, unable to protect the occupant if an accident was to occur.”

   NHTSA complaint #811544, filed 1997-04
4. 4
   Transmission and drivetrain

   Automatic transmission slipping or failing

   • 39 complaints (8%)
   • median 46,000 mi at 12.1 yrs old (1 states mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2007

   Owners describe lurching, slowing and stalling while driving, and loss of reverse after a stall. Some report transmission replacement more than once, and one describes a planetary gear pin letting go and breaking the case. Repair shops in the complaints said the clutch plates had seized together. Reported from about 46,000 miles upward, sometimes with a second failure around 67,000 miles.

   What to check: Check fluid condition and color, drive at steady and rolling speeds listening for slipping or delayed engagement, and confirm reverse engages without hesitation.

   2 excerpts from owner complaints in NHTSA records

   “I was heading home from work, when I felt my minivan start to lurch and slow down at the same time. I barely made it home. I had it looked at the next day and the repair shop said the clutch plates were frozen together and I was lucky that the transmission didn't explode or freeze-up(causung accidents) like some others that they have seen. I looked into this and there are more than a few horror stories on the internet concerning Plymouth automatic transmissions exploding, some with less than 300 miles. …”

   NHTSA complaint #762677, filed 2002-06

   “A frame broken while crossing rail road tracks at 40 MPH. Also, caused damages to transmission. Manufacturer notified ,and informed consumer that vehicle was out of warranty and over milleage.”

   NHTSA complaint #852044, filed 1999-10
5. 5
   Fuel system

   Fuel smell and leaks at injector seals or rail

   • 20 complaints (4%)
   • median 130,000 mi at 15.1 yrs old (1 states mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2008

   Complaints describe a strong gasoline smell in the cabin traced to leaking fuel injector seals, rail or pressure regulator, sometimes with a corroded clamp on the line to the tank. Owners report parts on backorder and note that recalls covering the fuel rail applied to later model years, not this one. Separately, some complain of oil pan leaks at the gasket. Reported from maintenance checks on vehicles with no mileage or from around 80,000 miles.

   What to check: Smell for fuel around the engine bay and under the hood after a cold start, and have the injector rail, seals and tank-to-line connections inspected for weeping or corrosion.

   2 excerpts from owner complaints in NHTSA records

   “The cylinder head/rocker arm shaft of my engine broke causing almost total loss of engine power. I also had a major fuel leak ( a potential engine fire hazard) and had to have my fuel rail assembly replaced.when the mechanic ordered these parts, there were 160 of the engine heads and even more of the fuel rail assembly on back order. The new engine head came with a special stud in the same area where the old part had been broken. My invoice from the repair shop indicates these repairs in more detail. I also still have the original parts. …”

   NHTSA complaint #710443, filed 1999-08

   “I got a strong odor of gas in the cab, took it to my mechanic who determined the fuel injector seals and rail were leaking. When he ordered the replacement part, we found out that the part is on a nationwide backorder. Chrysler tells me that this is not a recall for my vehicle. I have found out that the rail is a recalled part for the '93 - '97 voyagers. My question is should it be a recall, and why is the entire country out of this part? They are telling me they will ship some out on 1/21, but do not have enough to meet all the orders!!!!! …”

   NHTSA complaint #717464, filed 2000-01

Buying note. A 1991 Voyager is an old vehicle, so the brake system, belt hardware and body attachments are the things to inspect or have checked before purchase. Confirm which of the open recalls were actually completed, since several complaints show repairs that were never done or did not hold.

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.