Model year record

1991 Plymouth Voyager recalls & problems

The 1991 Plymouth Voyager has 8 safety recalls and 520 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (155 complaints).

Recalls8safety recalls

Complaints520filed by owners

Crashes · fires26 · 7reported in complaints

Injuries · deaths28 · 3reported in complaints

Safety recalls

StructureSep 2, 1999

Body › Hatchback/liftgate › Hinge and attachments

Recall 99V2130001,318,189 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: MINI VANS. THE BOLTS USED TO ATTACH THE STRUT TO THE BODY AND THE REAR LIFTGATE CAN ACCUMULATE FATIGUE DAMAGE IF THREE FACTORS COMBINE. IF THE BOLT IS LOOSE, THE GAS STRUT IS OVER-PRESSURIZED, AND THE FREQUENCY OF OPENING AND CLOSING CYCLES IS HIGHER THAN FOR THE AVERAGE CUSTOMER, THE BOLT CAN FAIL.
Risk: PERSONAL INJURY COULD OCCUR IF THE BOLTS BREAK ALLOWING THE LIFTGATE TO FALL SUDDENLY.
Fix: DEALERS WILL INSPECT FOR LOOSE FASTENERS, IF THE FASTENERS ARE LOOSE, THE STRUT (AND INTEGRAL BOLTS) WILL BE REPLACED. IF THE BOLT SHOWS EVIDENCE OF TORQUE, THE BOLT WILL BE REMOVED, LARGER WASHERS WILL REPLACE THE EXISTING WASHER AND THE BOLT WILL BE REINSTALLED AND HAND TIGHTENED TO THE TARGET TORQUED.

VisibilityJul 16, 1999

Windshield wiper/washer › Linkages

Recall 99V189000828,559 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: MINIVANS. THE LEFT HAND WINDSHIELD WIPER PIVOT DRIVE ARM WAS NOT MECHANICALLY STAKED TO THE PIVOT SHAFT.
Risk: THIS COULD ALLOW THE DRIVE ARM TO DISENGAGE FROM THE SHAFT LEADING TO A LOSS OF WIPER FUNCTION. THE DRIVER'S VISIBILITY WOULD BE IMPAIRED, INCREASING THE RISK OF A CRASH.
Fix: DEALERS WILL REPLACE THE LEFT HAND SIDE WINDSHIELD WIPER PIVOT ASSEMBLY.

Seat beltsSep 9, 1997

Front › Buckle assembly

Recall 97V1480001,100,000 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: PASSENGER MINI-VANS. COVERS ON THE SOLID STALK MOUNTED SEAT BELT BUCKLES CAN BECOME DISLODGED CAUSING THE RELEASE BUTTON TO STICK INSIDE THE COVER. THE BUCKLE WOULD THEN BE ONLY PARTIALLY LATCHED.
Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Fix: DEALERS WILL INSTALL A COVER RETAINING CLIP TO THE STALK MOUNTED BUCKLE COVER TO PREVENT DISLOCATION OF THE BUCKLE COVER.

Seat beltsSep 9, 1997

Front › Anchorage

Recall 97V1490001,100,000 vehiclesopened after NHTSA action (ODI)

Problem: VEHICLE DESCRIPTION: PASSENGER MINI-VANS. THE CENTER REAR SEAT, RIGHT OUTBOARD SIDE, SAFETY BELT ANCHOR HOOK CAN BECOME UNATTACHED FROM THE BODY ANCHOR POSITION.
Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Fix: DEALERS WILL REPLACE THE ANCHOR HOOK RETAINING CLIP WITH A REVISED PROFILE CLIP AND A COVER PLATE.

SteeringNov 18, 1996

Steering wheel/handle bar

Recall 96V229000675,000 vehiclesopened after NHTSA action (ODI)

Problem: THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.
Risk: IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTROL CAN OCCUR INCREASING THE RISK OF AN ACCIDENT.
Fix: DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY STEERING WHEELS SHOWING CRACKS WILL BE REPLACED. ALL OTHER VEHICLES WILL HAVE A REINFORCEMENT PLATE INSTALLED TO PREVENT STEERING WHEEL SEPARATION IN THE EVENT CRACKING OCCURS.

Service brakes, hydraulicJun 13, 1996

Antilock/traction control/electronic limited slip

Recall 96V099000321,000 vehiclesopened after NHTSA action (ODI)

Problem: THE ABS HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR CAUSING PUMP-MOTOR DETERIORATION.
Risk: IF THIS CONDITION OCCURS, THE ABS FUNCTION COULD BE LOST AND REDUCED POWER ASSIST WOULD BE EXPERIENCED DURING VEHICLE BRAKING INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Fix: DEALERS WILL TEST THE VEHICLE'S ANTI-LOCK BRAKE SYSTEM AND REPAIR THE VEHICLES IF NECESSARY. ALSO THE WARRANTY ON ALL ABS COMPONENTS WILL BE EXTENDED TO 10 YEARS OR 100,000 MILES (EXCEPT FOR THE BRAKE ACTUATOR PISTON ASSEMBLY AND THE PUMP-MOTOR ASSEMBLY WHICH WILL HAVE A LIFETIME COVERAGE). OWNERS WILL ALSO BE REIMBURSED FOR PREVIOUS ABS COMPONENT REPAIR COSTS.

Service brakes, hydraulicMar 10, 1992

Foundation components › Hoses, lines/piping, and fittings

Recall 92V03000010,492 vehiclesopened after NHTSA action (ODI)

Problem: THE ANTI-LOCK BRAKE SYSTEM HIGH PRESSURE PUMP MAY BE POROUS WHICH WILL RESULT IN BRAKE FLUID LEAKAGE.
Risk: FLUID LEAKAGE EVENTUALLY CAUSES THE LOSS OF BOTH THEANTI-LOCK BRAKE SYSTEM AND HYDRAULIC ASSIST FOR THE BRAKE SYSTEM, RESULTING ININCREASED LIKELIHOOD OF BRAKE LOCKUP AND INCREASED STOPPING DISTANCES, WHICHCOULD RESULT IN A VEHICLE ACCIDENT.
Fix: REPLACE THE ABS HIGH PRESSURE PUMP AND HIGH PRESSURE HOSE IF THE LAST SIX DIGITS OF THE BAR CODE LABEL ON THE PUMP ARE BETWEEN 052300 AND 059262.

Service brakes, hydraulicNov 1, 1991

Foundation components › Hoses, lines/piping, and fittings

Recall 91V19100080,000 vehiclesopened after NHTSA action (ODI)

Problem: THE ANTI-LOCK BRAKE SYSTEM HIGH PRESSURE HOSE MAY LEAK OR DETACH AT ITS CRIMPED END FITTING RESULTING IN THE DISCHARGE OF HYDRAULIC FLUID.
Risk: FLUID DISCHARGE EVENTUALLY CAUSES THE LOSS OF BOTH THEANTI-LOCK BRAKE SYSTEM AND HYDRAULIC ASSIST FOR THE BRAKE SYSTEM, RESULTING ININCREASED LIKELIHOOD OF BRAKE LOCKUP AND INCREASED STOPPING DISTANCES, WHICHCOULD RESULT IN A VEHICLE ACCIDENT.
Fix: REPLACE THE ABS HIGH PRESSURE HOSE WITH A HOSE OF DIFFERENT DESIGN AND CONSTRUCTION.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components	155	4	0	1	94,000 mi
Seat beltsFront › Anchorage; Front › Buckle assembly	105	3	0	9	—
StructureBody › Door; Body › Door › Hinge and attachments	73	4	1	6	143,715 mi
Power trainAutomatic transmission; Manual transmission	51	2	0	0	138,406 mi
Engine and engine coolingEngine; Engine › Gasoline › Belts and associated pulleys	44	0	1	0	—
VisibilityGlass, side/rear; Windshield	30	1	1	1	—
SteeringHydraulic power assist › Pump; Steering wheel/handle bar	28	1	0	2	—
Fuel system, gasolineFuel injection system; Storage › Tank assembly	24	0	1	0	—
Electrical systemIgnition; Wiring	23	0	3	0	—
Latches/locks/linkagesHatchback/liftgate › Lock; Doors › Latch	22	1	0	2	—
Vehicle speed controlAccelerator pedal	12	2	0	0	—
Air bagsFrontal	10	6	0	5	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Structure › Body › Hatchback/liftgate › Hinge and attachments
TL*THE CONTACT OWNS A 1991 PLYMOUTH VOYAGER. THE CONTACT STATED THE BOLT THAT HELD THE STRUT ON THE PASSENGER SIDE OF THE LIFTGATE FRACTURED AS IT WAS CLOSING. THE CONTACT STATED THAT THE LIFTGATE WAS NO LONGER OPERABLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN ID NUMBER: 99V213000 (STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS) IN 1999 BUT HAD NEVER RECEIVED THE RECALL REPAIR. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THE REPAIR WAS REFUSED. THE MANUFACTURER ADVISED THAT DUE TO THE AGE OF THE RECALL, THE CONTACT WOULD BE LIABLE FOR ONE HALF OF THE REPAIR COSTS. THE CONTACT STATED THAT THE MANUFACTURER SHOULD STAND BEHIND THE RECALL AND REPAIR THE LIFTGATE. THE…
Sep 8, 2010 · 185,102 miles
Service brakes, hydraulic › Antilock/traction control/electronic limited slip
TL* THE CONTACT OWNS A 1991 PLYMOUTH VOYAGER. THE CONTACT STATED WHILE DRIVING AT UNKNOWN SPEEDS, THE ANTI-LOCK BRAKING SYSTEM WARNING LIGHT ILLUMINATED ON THE DASHBOARD. THE DEALER ADVISED THE ABS SYSTEM WAS DEFECTIVE AND WOULD NEED TO BE REPLACED, THE REPAIR WAS PERFORMED ON THE VEHICLE, HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER ADVISED THEY WOULD CONTACT THE DEALER BUT WOULD NOT PROVIDE ANY ASSISTANCE. THE FAILURE MILEAGE WAS 79,000 AND THE CURRENT MILEAGE WAS 80,000.
Mar 10, 2010 · 79,000 miles
Service brakes, hydraulic
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. *TR
Jul 2, 2008 · 179,000 miles
Fuel system, gasoline › Fuel injection system
1991 VOYAGER WITH A FUEL LEAK. CONSUMER STATES THAT THE LEAK IS AT THE CROSS OVER PIPE ON THE FUEL RAIL. HE STATES THAT THE LEAK IS SO BAD THE VEHICLE CANNOT BE DRIVEN. HE WAS INFORMED THAT THE RECALL DID NOT APPLY TO THIS VEHICLE. *KB
Jan 1, 1901
Power train
1991 PLYMOUTH VOYAGER WITH TRANSMISSION PROBLEMS. CONSUMER STATES THAT THE TRANSMISSION SLIPS AND IS DIFFICULT TO MOVE THE SHIFT LEVER FROM PARK, REVERSE, NEUTRAL, AND DRIVE. *KB THE CONSUMER STATED THE SHIFTER BROKE.
Jan 1, 1901
Service brakes, hydraulic › Antilock/traction control/electronic limited slip
DT*: THE CONTACT STATED THE BRAKES DO NOT WORK PROPERLY. WHILE APPLYING PRESSURE THE PEDAL FELT SPONGY AND MUST BE PUMPED SEVERAL TIMES BEFORE THE VEHICLE WILL STOP. AN NHTSA RECALL, # 96V099000 WAS PERFORMED ON THE VEHICLE CONCERNING, THE SERVICE BRAKES, HYDRAULIC: ANTILOCK HOWEVER, THE RECALL DID NOT REMEDY THE PROBLEM. THE DEALERSHIP WOULD NOT OFFER A SECOND REPAIR WITHOUT CHARGE UNDER THE RECALL.
Jun 13, 2006 · 73,000 miles
Electrical systemFire
VEHICLE DIED. ATTEMPT TO RESTART FAILED. FIRE BURST FROM UNDER HOOD. ENTIRE VEHICLE, INSIDE AND OUT, BECAME ENGULFED IN FLAMES. TOTALLY BURNED INSIDE AND OUT. FATHER ABLE TO GET THREE SMALL CHILDREN OUT OF VEHICLE WITHOUT INJURIES. RANGER STATED THAT FIRE STARTED UNDER DASH.
Dec 24, 2005
Fuel system, gasoline › Fuel injection system › Fuel rail
SMELLED FUEL, FOUND FUEL RAIL LEAKING AT PRESSED JOINT LEADING TO OTHER SIDE, CAR UNDRIVEABLE, NOT YET REPAIRED. *JB
Nov 6, 2005 · 130,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

REAR LIFTGATE SUPPORTOpenLed to recall 97V079000
ON MAY 7, 1997, CHRYSLER FILED A DEFECT INFORMATION REPORT TO RECALL 436,000 1992 DODGE CARAVAN/GRAND CARAVAN, PLYMOUTH VOYAGER/GRAND VOYAGER AND CHRYSLER TOWN AND COUNTRY VEHICLES TO REPAIR THE LIFTGATE SUPPORTS; SAFETY RECALL 97V-079.ODI HAD INVESTIGATION THE REAR LIFTGATE SUPPORT PROBLEM FOR 1991-1993 CHRYSLER MINIVANS IN PE 96-035 AND EA96-027.AT THE TIME OF CLOSING EA96-027 ON MAY 16, 1997, A SAFETY RELATED DEFECT TREND HAD NOT BEEN IDENTIFIED ON THE 1991 AND 1993 MODELS.SINCE THE CLOSING OF EA96-027, ODI HAS RECEIVED 34 COMPLAINTS OF REAR LIFTGATE SUPPORT ATTACHING BOLT FAILURES, INCLUDING TEN INJURIES, ON THE SUBJECET VEHICLES.IT IS RECOMMENDED THAT A RECALL QUERY BE OPENED TO DETERMINE THE SCOPE OF LIFTGATE SUPPORT FAILURES ON THE SUBJECT VEHICLES.CLOSING NOTE: ON JULY 19, 1999, DAMILERCHRYSLER AGREED TO RECALL 1991, 1993, AND 1994 MODEL YEAR VEHICLES TO REMEDY REAR LIFTGATE…
RQ99004 · opened Apr 19, 1999
ALLEGED REAR LIFTGATE SUPPORT FAILUREClosedLed to recall 97V079000
THE RETAINER BOLT OF THE REAR LIFTGATE SUPPORT CYLINDERS MAY SHEAR RESULTING IN SUDDEN COLLAPSE OF THE REAR HATCH DOOR.
EA96027 · opened Oct 31, 1996 · closed May 16, 1997
INCONSISTENT SAFETY BELT BUCKLEClosedLed to recall 97V148000
safety belt buckle hosing slips down, pinching the red release button.owners report having trouble opening and closing them many allege belt unlatches while driving because of the release buttom
EA96016 · opened Jun 28, 1996 · closed Dec 17, 1997
ALLEGED REAR LIFTGATE SUPPORT FAILUREClosedLed to recall 97V079000
THE RETAINER BOLT OF THE REAR LIFT GATE SUPPORT CYLINDERS MAY SHEER RESULTING IN THE SUDDEN COLLAPSE OF THE REAR HATCH DOOR.
PE96035 · opened May 6, 1996 · closed Oct 31, 1996
SAFETY BLT LATCH OPERATIONClosed
There is no summary currently available
PE96008 · opened Jan 25, 1996 · closed Jun 28, 1996
STEERING WHEEL SEPARATIONClosedLed to recall 96V229000
AFTER AN EXTENSIVE INVESTIGATION AND ANALYSIS, CHRYSLER HAS IDENTIFIED THE DEFECT AS A FATIGUE FAILURE, ORIGINATION IN THE HEAT AFFECTED REGION OF THE PROJECTION WELDS OF THE STEERING WHEEL HUB TO STEERING WHEEL ARMATURE ATTACHMENT.THE HUB IS THE PORTION OF THE STEERING WHEEL ASSEMBLY THAT CONNECTS IT TO THE STEERING COLUMN SHAFT AND IS ATTACHED TO THE UNDERSIDE OF THE STEERING WHEEL ASSEMBLY BY 4 WELDS.IF CRACKS DEVELOP IN THE HEAT AFFECTED REGION OF THE WELDS AND PROPAGATE THROUGH THE STEERING WHEEL ARMATURE TO EACH OF THE WELDS, THE STEERING WHEEL CAN SEPARATE FROM THE HUB.THIS IS A SLOW PROGRESSIVE FAILURE WHICH NORMALLY OCCURS AT HIGH MILEAGE.IN SOME CASES COMPLAINANTS HAVE REPORTED A LOOSENESS OR WOBBLING OF THE STEERING WHEEL PRIOR TO SEPARATION.TO REMEDY THIS DEFECT, CHRYSLER WILL INSPECT THE STEERING WHEELS OF THE AFFECTED VEHICLES FOR CRACKS IN THE HUB AREA.IF ANY CRACKS ARE…
EA95029 · opened Sep 26, 1995 · closed Nov 13, 1996
ABS BRAKING SYSTEM FAILSClosedLed to recall 96V099000
There is no summary currently available
EA94028 · opened Jul 29, 1994 · closed Jun 24, 1996
ABS BRAKING SYSTEM FAILSClosed
There is no summary currently available
PE94024 · opened Mar 7, 1994 · closed Jul 29, 1994
LIFTGATE LATCHESClosed
LIFTGATE LATCHES IN THE SUBJECT VEHICLES HAVE FAILED IN LOW AND MODERATE SPEED IMPACTS RESULTING IN OCCUPANT EJECTIONS, INJURIES, AND FATALITIES.THERE ARE TWO FAILURE MODES ASSOCIATED WITH LATCH FAILURE: FORK BOLT-DETENT LEVER BYPASS, AND INERTIAL UNLATCHING.NHTSA ANALYSES OF CHRYSLER AND PEER MINIVANS TOOK THE FORM OF STATIC AND DYNAMIC CRASH TESTING, ENGINEERING EVALUATIONS, COMPLAINT AND FIELD ANALYSES, AND REAL WORLD DATA ANALYSES.A TECHNICAL REPORT DISCUSSING THESE ANALYSES CAN BE FOUND IN THE ENGINEERING ANALYSIS TECHNICAL REPORT IN THE PUBLIC VIEWING FILE.CHRYSLER HAS ADVISED NHTSA THAT IT WILL CONDUCT A CAMPAIGN TO REPLACE THE LATCHES ON ALL THE SUBJECT VEHICLES.THE CHRYSLER CAMPAIGN WILL CONSIST OF NOTIFICATION LETTERS TO ALL OWNERS; FREE REPLACEMENT OF ALL LATCHES WITH STRONGER, SAFER LATCHES REGARDLESS OF THE AGE OF THE MINIVANS; NATIONAL ADVERTISING TO PROMOTE CUSTOMER…
EA94005 · opened Jan 31, 1994 · closed Oct 25, 1995
MELTED THROTTLE CABLESClosed
There is no summary currently available
PE93056 · opened Jun 9, 1993 · closed Sep 14, 1993
WINDOW SHATTERINGClosed
There is no summary currently available
PE92053 · opened Jun 8, 1992 · closed Oct 9, 1992
SAFETY BLT ANCHORAGE BRKSClosed
There is no summary currently available
PE92028 · opened Mar 11, 1992 · closed Jul 20, 1992
BRAKING PERFORMANCE LOSSClosedLed to recall 91V191000
ABS SYSTEM LEAKS ARE ALLEGED BY CONSUMERS WHICH RESULT IN COMPLETE BRAKEFAILURE. SEVERRE LEAKING OCCURS WHILE THE VEHICLE SITS FOR SEVERAL HOURSRESULTING IN COMPLETE LOSS OF FLUID. LEAKS ARE APPEARING IN BOTH THE HIGHAND LOW PRESSURE LINES POSSIBLY DUE TO A FAULTY SEAL OR COUPLING. ONECOMPLAINT ALLEGES FLUID BEING FORCED OUT OF BRAKE RESERVOIR WHEN ENGINE ISSTARTED, POSSIBLE POINTING TO A FAULTY CHECK VALVE IN THE ACCUMULATOR.
PE91094 · opened Jul 5, 1991 · closed Nov 26, 1991
ABS CONTROL FAILUREClosed
There is no summary currently available
PE91093 · opened Jun 28, 1991 · closed Oct 23, 1991