Body complaints by model year
Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
What owners report
Front strut pushing through body of van. We've spoken to a few mechanics/dealers who have been seeing alot of the same thing with this make/model van. No incident has occurred yet but the potential is there. We would like to bring attention to this so NHTSA can communicate with the dealerships and resolve. Maybe a recall should be considered? This is potentially very dangerous if owners are not aware of the situation. It also is a costly repair for an issue that seems to be very common in this specific vehicle 2000 Plymouth Grand Voyager. Please help us resolve.
Consumer called complaining about having problems with the vehicle which is leaking water not knowing where it is coming from. Dealer has inspected and changed the door rubber seal. And the problem is recurring. Please provide further information. Ts
The vehicle caught fire when I was about to leave my house, I had started it and then was about to put it in gear when it exploded, I had to jump out the passenger side and then there was another explosion followed by another.
Metal fatigue-8 inch crack has been found by me on the drivers side where the mcpherson strut is connected to the body fender mounting area. I have never seen anything like this. Car has never been in a front accident and is garage kept. I have been the sole owner of the vehicle. If this crack continues this car will no longer function and have to be junked. I believe this is a Chrysler manufacturing defect. Chrysler should be completely responsible for its repair or alternate solution provided to me.
>> Chrysler did repair the strut at no cost and rented us a handicap van while ours was being fixed. At first (6 times) we were told we were out of warranty, end of story. So our handicap van was worthless. Once I uncovered a bulletin acknowledging the problem Chrysler's tune changed. Make : Plymouth model : Voyager year : 1997 service bulletin num : 2304402 date of bulletin: oct 14, 2002 > NHTSA item number: 10000317 > component: structure:body they had already made parts to fix this problem. It is ridiculous I had to go to the extent I did to solve this problem. We were told that if the strut goes all steering is lost. So the public is at risk but that is acceptable to Chrysler. Instead of notifying all >> owners of the potential problem (about $300 to fix) Chrysler feels peoples lives >> are not worth the trouble. …
Opened the rear hatch on the vehicle, let go, and the hydraulic strut failed -- instead of opening fully, the hatch slammed shut. It turns out that the bolt holding the right strut on sheared off. Apparently, the other strut was no longer working, and the stress of the weight of the hatch on the right strut caused the bolt to fail. Fortunately. No one was under the hatch or was injured. Replaced both struts. I am reporting this because of the failure of the bolt -- there was no warning that the rear hatch would slam shut, as it appeared to operating perfectly until the failure. It could have caused a serious injury, especially to children.
Vehicle safety issue (Chrysler TSB 23-044-02), rust through of upper strut towers 1996-2000 Chrysler, Dodge, Plymouth minivans. Collapse of strut tower would result one or more of the following: 1/ sudden change of steering geometry; total loss of steering; lockup of one of the front wheels, blowout of one of the front tires. This is a problem which Chrysler has known about for years. They only issued a TSB once most of the vehicles involved (96-98) were beyond the manufactures rust perforation warranty. This should not be merely a "service" recall, but a "safety" recall. This is due to a manufacturing defect which failed to seal between component panels allowing moisture to penetrate and cause hidden rust issue which reveals itself only when the structural damage is already done. The recommended repair is also questionable -- utilizing only epoxy to afix a cap to the top of the strut. …
Dodge caravan strut tower rust perforation - significant rust perforation on the right and left hand strut towers severely weakens the structural integrity of these main load path members. Failure of the strut towers would lead to uncontrolled displacement of the upper end of the strut resulting in loss of control of the vehicle. Since the possibility of failure exists at any time while driving the vehicle, should it occur at highway speeds, serious bodily injury and death are likely.
Frequently asked questions
Which Plymouth Grand Voyager years have body problems?
By NHTSA complaints, the 1996 (42), 1995 (19), 1998 (13), 1997 (12) and 1999 (9) model years. Body complaints make up 7% of all complaints for the 1996.
Is there a recall for Plymouth Grand Voyager body problems?
No. NHTSA lists no body & structure recall for any Plymouth Grand Voyager model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Plymouth Grand Voyager body problems start?
Across all years, half of the complaints with a recorded mileage happened before about 108,000 miles; 9% happened before 50,000 miles.
What part fails most often?
Owners most often name the body › door (45 mentions), followed by the body (17).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.