Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
Me and my son was driving down the interstate when all of the sudden my speedometer stopped working and the rpms was going up to a dangerous zone ,I let off the gas to try and avoid a engine blow up and the rpms was still quite high, I manged to get us off with out getting ran into from behind, I went 25 MPH going home at the rate of rpms at 3 1\2 to 4 ,I have no ideal as to what is going on but a few things I have read so far sounds like maybe emissions or trasmission, I live on a fixed income and disabled ,I wished I knew about all the recalls and the troubles the Voyager had before I bought it, well some one wish me luck , thanks
Tl contact owns a 1996 Plymouth Voyager. The contact stated that while driving 30 MPH, he smelled a fuel odor. The contact noticed a fuel leak from the rear of the fuel tank. The dealer stated that the fuel module needed to be replaced. The vehicle had not been repaired. The current and failure mileages were approximately 92,000.
I am exhibiting the same problem with my Chrysler Voyager van with the 3.0 v6 engine. I have gas leaks and cracks from the fuel rail. I called Chrysler 3 times and they refuse to include my type of engine even thought it is the same fuel rail and problem.. Help? Recall 00V268000: fuel rail cracks/leaks
Consumer parked the vehicle and shut it off. Then consumer came back to the vehicle and noticed that it was on fire from under the rear of the vehicle. Consumer called the fire and rescue departments to put the fire out. The fire department informed consumer that the fire started from the fuel tank.
Vantage conversion van fuel line failure. Service order reads: "ss rubber fuel line was installed by whomever install wheel chair carriage from gas tank to frt of engine. Rubber line rotted away. Found fuel line leaking from top of engine replaced line from fuel tank to fuel rail."
While driving at any speed vehicle completely shutdown without warning due to a problem with fuel pump. Problem occurs when fuel tank is full. Dealer recommends that tank remains at half to prevent problem. Please give any further details.
Fuel tank: rollover valve located on top of plastic fuel tank is welded into fuel tank at manufacture. First tank failed at 6000 miles on vehicle, tank cracked around weld at rollover valve site. Fuel leakage and vapor leakage ensued until tank replaced by dealer (quality Chrysler Jeep Plymouth Eagle, albuquerque, nm in aug 1996). The replacement tank developed a leak at the same site, weld of rollover valve to tank body, in December 1998. Both tanks failed in similar manner, both failures cause raw fuel and vapor to leak continuously from tank. Problem with multi-function switch (turn signals, high/low beam, wiper, washer switch, steering column mounted. When driving, the front and rear windshield wipers will automatically turn on by themselves. First multifunction switch replaced by quality Chrysler Plymouth Jeep Eagle, albuquerque nm, late 1996. Dealer replaced multifunction switch. …
My engine has had several problems, and every time they "fix" it, something else happens. It is still sputtering and the check engine light came on again even after I spent 650.00 to have it fixed a few weeks ago. Now, yesterday they did yet another fuel system recall, and today (4/15/00) the check engine light came on and it is sputtering again. I am sick of sinking money into this van and it is not even paid for. Also, the number of fuel system and engine recalls they have had is dangerous. Most of their recalls have had to do with the possibility of the van catching fire. I hate to think about what could happen to my children while riding in this vehicle. They need desperately to put out a recall on the head gasket leaking oil. I had to have a $1,000.00 head gasket job at 60,000. That is ridiculous. …
Fuel tank leak occurred at a platisc weld point on the top of the tank where a line went in. This tank is essentially a static component and a leak at a weld joint I consider is a manufacturing defect. I've taken a few autos beyond this amount of mileage and years without any fuel tanks failures of this type. This failure appeared during vacation when parked on a grade with thefront of the van pointed downhill. This caused a rather large pool of fuel to sit on the ground, enough for the local officials to send a fire truck to the scene. When I returned to our van it was determined by the fire offical that it not be driven. The van was towed to a Chrysler dealer ship and the next day the leak was found. They could not supply a tank but since the leak was on top said it was safe to drive as long as I filled the tank no more than three quarters full. …
Leaking rollover valve on fuel tank. I spoke to daimlerchrysler on 12/19/2000 about safety recall #665- fuel filler tube rollerover valve & ground strap (NHTSA 95V236000) an was told that since my vehicle was built nine (9)days (on 8/19/95) after the recall end date 8/10/95 that they would not be willing to replace the tank. I was informed that I would have to replace tank at a cost of $697.02 then send in receipt for review. I feel that since I have seen many cases in your office of defects investigations files ( odi-835261, odi-814712, odi-510678, odi-801764, odi-853149, odi-986406, odi-809874, odi-870842, odi-523381, odi-547150, odi-974927, odi-974005, odi-811247, odi-980479 & NHTSA action # ea97002, pe95053, pe96051,) that daimlerchrysler should step up and replace this at no cost since this is a known product failure. …
Related recalls
Fuel system, gasoline › Fuel injection system
Vehicle description: Mini vans built with 3.3l and 3.8l engines have fuel rails with nitrole rubber o-ring seals that can degrade over time. Fuel leakage from the underhood fuel injection fuel rail could result, increasing the likelihood of a vehicle fire.
Remedy: Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing o-rings continue to degrade. Owner notification began on January 25, 2002.
Fuel system, gasoline › Delivery › Fuel pump
Vehicle description: minivans. Fuel can leak from the fuel tank at the interface of the fuel pump module attachment.
Remedy: Dealers will replace the fuel pump module attaching nut with a nut that includes tighter design tolerances. The sealing o-ring will also be replaced.
Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
A static electric charge can build up on the ungrounded metal section of the fuel filler tube.
Remedy: Dealers will install a ground strap for the fuel filler tube.
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
The fuel tank rollover valve can allow fuel to pass into the vapor canister resulting in the potential for fuel leakage.
Remedy: Dealers will replace the fuel tank filler tube with a filler tube that has an additional rollover valve. The associated rollover valve vapor hoses will be rerouted.
NHTSA investigations
Post-collision fuel system integrity
There is no summary currently available
Post collision fuel system
Fuel System complaints in other Voyager years
Frequently asked questions
How common are fuel system problems on the 1996 Plymouth Voyager?
NHTSA has 108 complaints about the fuel & propulsion system of the 1996 Plymouth Voyager, 14% of the model year's 756 complaints. The component named most often is storage › tank assembly (50 mentions).
Is there a recall for 1996 Plymouth Voyager fuel system problems?
Yes — NHTSA recall 00V-268 (fuel injection system, Sep 13, 2000); NHTSA recall 99V-216 (fuel pump, Aug 9, 1999); NHTSA recall 96V-002 (filler pipe and cap, Jan 16, 1996). Recall repairs are free at authorized dealers.
At what mileage do 1996 Plymouth Voyager fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 33% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 4 fires and 5 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.