Which parts fail
Components named in complaints (air conditioning, heater, defroster, HVAC controls).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Plymouth Voyager owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 1996 Chrysler Voyager. After purchasing the vehicle, the defogger failed to operate normally. The driver had to stop the vehicle in order to clean the windows. There have been several failures with the vehicle since it was purchased. The engine was rebuilt and the serpentine belt was replaced on five occasions. The steering was replaced incorrectly by a dealer and was authorized by the manufacturer to be replaced. The brakes and the heating system were replaced under the extended warranty; however, the brakes were replaced four times. The contact was charged $100 per visit. Invoices are available if needed. A complaint was also filed with the state attorney general. The contact is disabled and aware of the safety risk involved in the numerous vehicle failures. On March 27, 2008, the dealer replaced the manifold and cylinder. …
Dt: the contact stated there were several safety defects within vehicle. The service dealer attempted to repair the vehicle numerous times. There was a problem with the defrosting system, the air conditioning belt, heater core, and heater blower, they were all replaced. The replacement of these parts did not solve the defrosting problem. The steering column shook while driving at normal speeds. The dealer has not been able to diagnose the source of the steering vibration. There was a squeaking noise in the brakes. The dealer said this was normal because the vehicle was not in use for a long period of time. The dealer indicated the noise would end with normal use, but the noise continued. Updated 12/7/2005 -
Dt: the contact stated since the purchase of used vehicle the defroster did not work. Without use of the defroster there was poor visibility. She took the vehicle to the dealer. The dealer has made several attempts to repair this problem. However, they have been unable to correct this problem. The manufacturer was contacted , and they offered no assistance. Updated 11/29/2005 -
The evaporator for the air conditioner has developed a leak and I have lost all coolant. The repair costs are substantial because the front dash has to be removed to replace the evaporator. Although my Mini-van is less than 3 years old, it is out of warranty due to the mileage. A friend of mine who owns an autobody shop mentioned that he has replaced quite a few evaporators in Voyager & caravan Mini-vans recently. Is this a common problem with these Mini-vans?
Power steering went out when driving through mudd puddles at 40 MPH or in car wash. Taken to dealer, belt had come off. Repaired it, but had no answer why it happened. This has happened lots of times. Also, windshield wipers came on while driving, switch has been replaced 5 times. The main belt failed. The water pump failed. The transmission was leaking. The A/C compressor went out burning on freeway.
The battery failed after 2 1/2 years. The air conditioning system failed after 1 month. It was repaired. It needed freon again two months later. It failed again 1 1/2 years after purchase, at which time we paid to have the system repaired. It has failed for the fourth time 3 years after purchase. The transmission suddenly failed three years after purchase, unable to go into reverse.
The air-conditioner failed to work properly during the first hot spell of the year. The dealer diagnosed a coolant leak. Although it was a slow leak that very likely began while the vehicle was under warrenty, Plymouth would only pay 70% of the repair bill because the problem was discovered after the 36000 mile warrenty ran out. The cost of diagnosis was not covered at all.
Ther was a strong fuel odor outside of vehicle, consumer had taken vehicle to dealer, who noticed a leak at rollover valves. Dealer stated that entire fuel tank needed replacement. Consumer stated problem seems to have been in existance for a number of years, also air condition not cooling properly, and the fan motor blower seems to be inoperative.
Front motor mount very bad and engine rocks back and forth and sometimes jerks when coming to a stop. Heater doesn't work on all setting for air. Steering bad, knocks on rough streets and makes bad noise when turning the steering wheel. Smell fuel inside of the vehicle when putting fuel in the tank and sometime smell it when regualar driving.
In April 2003, the vehicle was taken to an auto body shop for maintenance on the air conditioning. The mechanic noticed the strut towers were rusting. The consumer then took the vehicle to Chrysler, who stated the problem was not normal. The consumer called the manufacturer, who would not cover any of the cost.
AC & Heater complaints in other Voyager years
Frequently asked questions
How common are ac & heater problems on the 1996 Plymouth Voyager?
NHTSA has 30 complaints about the a/c & heater of the 1996 Plymouth Voyager, 4% of the model year's 756 complaints. The component named most often is appliance › air conditioner (26 mentions).
Is there a recall for 1996 Plymouth Voyager ac & heater problems?
No. NHTSA lists no a/c & heater recall for the 1996 Plymouth Voyager, though it has 9 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Plymouth Voyager ac & heater problems start?
Half of the complaints with a recorded mileage happened before about 63,000 miles.
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.