1996 Plymouth Voyager Problems

What owners report

Owners of this model year most often describe air bag system trouble — warning lights that stay on, horn and cruise control that stop working, and air bags that did not deploy in a collision — along with windshield wipers that run on their own or quit mid-stroke and repeated transmission failures. Many of the reports come in from roughly 60,000 to 120,000 miles, and several owners describe the same part failing more than once.

1. 1
   Air bags

   Air bag light on; horn and cruise control stop working

   • 144 complaints (19%)
   • median 97,900 mi at 7.8 yrs old (18 state mileage)
   • 19 mention a crash, fire or injury
   • owner-quoted repair $375 (median of 9 quotes)
   • filed 1995–2017

   Complaints describe the air bag warning light staying lit while driving, often together with a horn and cruise control that no longer work and a flapping or ticking noise when turning the wheel. Several owners link this to the clockspring in the steering column and report that a recall repair covered only part of the problem, leaving the light on or the cruise control inoperative. Others describe air bags that did not deploy in a frontal or side impact, including after recall work had been completed. Mostly reported between about 60,000 and 130,000 miles, with several at or near 100,000 miles.

   Recall 02V293000

   What to check: With the key on, confirm the air bag light goes out after the bulb check, and test the horn and cruise control. Ask whether recall 02V293000 (clockspring) was performed and whether the horn, cruise and air bag light worked afterwards.

   2 excerpts from owner complaints in NHTSA records

   “I completed a recall on the air bag component of my 1996 Plymouth Voyager in july 2003. I was involved in a t-bone collision on january 26, 2004 where I hit the other car in his driver door going approx. 40 MPH. Neither of my air bags opened.”

   NHTSA complaint #10059927, filed 2004-02, 176,500 miles

   “Basically, this vehicle has had several electrical problems since I have owned it ( I am the original owner). The windshield wipers go on intermittently , I have put 3 or 4 new batteries in it. The alarm system does not function properly. I have heard the NHTSA is investigating the air bag, horn and cruise control problem. Has any decisions been made so that I wont have to pay $300.00 to fix this defect. ****dimsii ivoq entry posted after 12/12/02 cut-over to artemis****770839”

   NHTSA complaint #10006648, filed 2003-01, 95,800 miles
2. 2
   Transmission and drivetrain

   Transmission slips, loses gears or fails

   • 69 complaints (9%)
   • median 72,000 mi at 7.6 yrs old (15 state mileage)
   • 3 mention a crash, fire or injury
   • filed 1996–2015

   Complaints describe jerking, clunking and a transmission that stops pulling or loses a gear while driving, sometimes leaving the van unable to move. Several owners report the transmission was replaced, in some cases more than once, and that the same behavior returned. Shops reportedly could not duplicate the problem or found only an unrelated misfire code. Often reported between roughly 50,000 and 130,000 miles, including a few below 60,000 miles.

   1 related service bulletin

   What to check: Test drive from cold through all gears, including overdrive and reverse, and check for delayed engagement, clunking or a flashing overdrive light. Ask for transmission service records and whether fluid was leaking.

   2 excerpts from owner complaints in NHTSA records

   “I am one of the many many customers that are experiencing complete failures with the chrysler 41te ultradrive transmissions. In my case I hade a complete transmition replacement at 79,000 miles. At 123,000 miles while pulling into traffic the vehicle stopped moving and the engine started revving very high. I hade the vehicle towed to the dealer that had installed the first transmission. I was informed that the transmission was over its 36,000 warranty and needed to be replaced. …”

   NHTSA complaint #10003277, filed 2003-01, 123,000 miles

   “On a family trip to north carolina, the transmission of our 1996 Plymouth Voyager lost third gear traveling in heavy traffic along I-95 south of richmond, va. Luckily my son was able to pull off the side of the road and travel a few miles without third gear to a chrysler repair shop. Since the shop was closed we had to rent a van to complete the trip and return on monday to find out what happened. The repairs were not covered under a warranty because chrysler gave me a 6 year/100,000 mile warranty. …”

   NHTSA complaint #10069666, filed 2004-01, 57,382 miles
3. 3
   Engine cooling

   Engine oil leaks and stalling or loss of power

   • 283 complaints (37%)
   • median 89,725 mi at 8.0 yrs old (38 state mileage)
   • 14 mention a crash, fire or injury
   • owner-quoted repair $770 (median of 12 quotes)
   • filed 1995–2017

   Complaints describe oil leaking from the top of the engine, in some cases heavily enough that oil had to be added every few days, and oil reaching the steering rack and exhaust area. Others report the engine losing power, bucking, backfiring and stalling, sometimes restarting after a wait and sometimes not. Owners mention repairs such as an engine computer, coil pack and crankshaft sensor without a lasting fix. Reported from about 45,000 to 140,000 miles, with several around 90,000 to 120,000 miles.

   Recall 96V006000

   What to check: Check for oil residue around the top of the engine, the cylinder head area and above the steering rack, and look for oil drips underneath. Ask whether the 96V006000 cylinder head oil galley plug recall was done.

   2 excerpts from owner complaints in NHTSA records

   “Engine and cooling system failure over faulty plug, I.e. (96v006000). Engine leaked out oil and cooked the engine. Now car sits, insured, in my driveway while I continue to make payments on it.”

   NHTSA complaint #10047296, filed 2003-11, 140,000 miles

   “In late june of 2004 vechicle had stalled while driving for no apperent reason and would not start. The emc was replaced. Five months later it repeated the same problem... All wiring has been checked emc replaced, coil pack replaced, crank shaft sensor replaced and the dealership cannot find the problem after 6 weeks.”

   NHTSA complaint #10104129, filed 2004-12, 16,000 miles
4. 4
   Visibility (wipers, defrost, mirrors)

   Windshield wipers run on their own or stop working

   • 61 complaints (8%)
   • median 95,800 mi at 7.7 yrs old (9 state mileage, few)
   • owner-quoted repair $544 (median of 6 quotes)
   • filed 1996–2009

   Owners report the front wipers switching on by themselves, sometimes as soon as the ignition is turned, and other times stopping mid-stroke or failing to start at all, including during rain. In cold weather some describe the blades sticking to the glass. Complaints mention replacing the switch, motor and relays without solving it, and one owner was told the next step was the computer. Spread fairly evenly from about 60,000 to 165,000 miles, with several reports below 100,000 miles.

   What to check: Run the wipers through every delay setting and the wash cycle, and watch for them parking correctly or starting on their own. Ask whether the wiper switch, motor or relay has already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I own a 1996 Plymouth Voyager and on this min van the wipers act very erratic. They work when they want. Sometimes they won't shut off and other times they will not come on at all or stop right in the middle of your view. I also have an issue with the serpentine belts popping off the drive line leaving you with no power steering or power brakes and completely disables the vehicle. I also experience issues with the rear shocks. The bolts come loose and detaches the rear shick from the van leaving it quite uncontrollable while driving. …”

   NHTSA complaint #10209285, filed 2007-11, 116,250 miles

   “We bought a Plymouth Voyager and we have had steady problems with the windshield wipers. Either they stop in the middle of a path and just quit working. Two years ago they stopped working at all, luckily we lived in wyoming with little rain. Last year we moved to florida and they worked for a while and now stopped again. We have replaced the switch ( as the dealership suggested) but it did not help, ( 89.00) then we were told it was a motor so we replaced that at 110.00, no difference, the relays are good an now they think it is the computer. …”

   NHTSA complaint #10093314, filed 2004-09, 94,000 miles
5. 5
   Electrical system

   Corroded front strut towers

   Mentioned in 4 of 60 sampled complaints

   Owners describe rust under the hood along the upper strut mounts, with the tower plate corroding and eventually pushing through or cracking. Some report repairs with a cap or full replacement of the tower, and complaints describe noises over bumps and reduced steering control once the metal gives way. Owners say they were told nothing could be done without a recall. Mostly reported between about 90,000 and 140,000 miles, usually on vehicles old enough for corrosion to set in.

   What to check: Open the hood and inspect the tops of both front strut towers for rust, flaking, cracks or patches; press around the mount and look for perforation. Have a shop check the strut mounting area from below before buying.

   2 excerpts from owner complaints in NHTSA records

   “Dt: the consumer noticed a line of rust under the hood where the vehicle mounts to the body. Front two struts mount into body where the plate corroded , and it will eventually push through. Two weeks ago replaced one of the struts on the driver's side because it pushed through plates. Contacted Plymouth , who was ignoring the problem. The upper strut tower corroded.”

   NHTSA complaint #10125763, filed 2005-07, 152,000 miles

   “Front strut tower corrosion perforating attachment surface on 1996 chrysler grand Voyager. Attachment point deteriorates causing the front suspension to collapse making the vehicle unable to steer causing collision with another vehicle or object unavoidable.”

   NHTSA complaint #10156516, filed 2006-05, 138,800 miles

Buying note. This is an old van, so condition matters more than the model itself: check the strut towers for rust, confirm the air bag light, horn and wipers all behave, and look for transmission or oil-leak symptoms on a cold test drive. Ask for records of any recall work (clockspring, fuel system, cylinder head plug) and of transmission replacements.

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.