1996 Plymouth Grand Voyager Fuel system Problems

AFFECTED COMPONENT: BODY CONTROL MODULE THE BCM CONTROLS THE FOLLOWING: WIPERS, FUEL PUMP, VEHICLE POWER AND MUCH MORE. DURING A RAINY DAY IN OREGON CIRY OREGON, THE BCM FAILED. THE CAR WAS MOVING INTO A PARKING LOT AT LESS THAN 20 MPH. IN THE PARKING LOT WAS A POLICE VEHICLE. WHEN THE BCM FAILED, THE VEHICLE LOST FUEL PRESSURE AND THEREFORE ENGINE POWER THEN POWER BRAKING, POWER STEERING AND THE WIPER CONTROL WENT ERRADIC. I MANAGED TO GET THE VEHICLE STOPPED, NARROWLY MISSING THE POLICE VEHICLE. I HAD NO POWER BRAKES, NO POWER STEERING, AND THE WIPERS STOPPED. THE BCM WAS TO BLAME. HAD THIS OCCURRED AT HIGHWAY SPEEDS, I DON'T LIKE TO THINK WHAT MAY HAVE HAPPENED!!!

NHTSA ID

11166547

Incident

Dec 17, 2016

Mileage

205,000 mi

WHILE DRIVING AT ANY SPEED (AROUND 65 MILES) MY VEHICLE SUDDENLY SHUTDOWN WITHOUT WARNING DUE TO FUEL PUMP. I HAVEN'T FIXED YET. AND IT HAS A ELECTRICAL PROBLEMS TOO. *TR

NHTSA ID

10678981

Incident

Oct 15, 2014

Mileage

180,000 mi

TL*THE CONTACT OWNED A 1996 PLYMOUTH GRAND VOYAGER. WHILE DRIVING IN REVERSE APPROXIMATELY 1 MPH HE SMELLED AN ODOR OF GASOLINE AND THE VEHICLE ENGULFED INTO FLAMES. THE FIRE BEGAN UNDERNEATH THE HOOD OF THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. THE VEHICLE WAS DESTROYED AND TOWED TO AN INSURANCE LOT. THE FAILURE WAS NOT DIAGNOSED AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 160,000. UPDATED 01/14/11*LJ

NHTSA ID

10367315

Incident

Nov 22, 2010

Mileage

160,000 mi

1996 PLYMOUTH GRAND VOYAGER HAD AN ENGINE FIRE DUE TO A LEAKING FUEL RAIL - INVESTIGATION REVEALED THE RAIL WAS UNDER AN OPEN RECALL THAT WAS NEVER FIXED AND I NEVER RECEIVED NOTICE OF IT. *TR

NHTSA ID

10278710

Incident

Jul 9, 2009

Mileage

148,000 mi

SMELL OF GAS AFTER DRIVING FOR ABOUT 20 MIN. LEAD TO A POP SOUND FROM UNDER VEHICLE. SMOKE FILLED THE INSIDE OF THE VAN AND AFTER I BROUGHT IT TO A STOP ON A MEDIAN THE VEHICLE WAS ENGULFED IN FLAMES BEFORE I MANAGED TO EXIT. AFTER EXITING THE VEHICLE AND HAVING THE FIRE PUT OUT SOON ON WITH USE OF A FIRE EXTINGUISHER I NOTICED THE EVAP CANISTER HAD DROPPED ALL OF ITS CHARCOAL. POSSIBLE THAT GAS WAS BEING DIRECTED INTO THIS CANISTER AND WHEN IT POPPED THE FUMES AND GAS IGNITED FROM THE EXHAUST SYSTEM. *JB

NHTSA ID

10204171

Incident

Sep 26, 2007

Mileage

142,000 mi

MY 1996 PLYMOUTH GRAND VOYAGER MINI-VAN 3.3 LITER V6 2 WHEEL DRIVE BROKE DOWN. APPARENTLY IN THE TRANSPORT, LOADING, OR UNLOADING OF THE VEHICLE ON MY TRAILER, ONE OF THE MUFFLER MOUNTS BECAME DISCONNECTED AND THE OTHER MUFFLER MOUNT THE BOLT INTO THE FRAME WAS PULLED OUT. THIS CAUSED THE MUFFLER AND EXHAUSE TO SHIFT. I DID NOT NOTICE THIS PRIOR TO OPERATION OF THE VEHICLE AFTER PERFORMING THE INITIAL REPAIRS THAT CAUSED THE BREAKDOWN (WATER PUMP / SERPENTINE BELT FAILURES). THE SHIFT OF THE MUFFLER CAUSED MY FUEL LINE AND GAS TANK TO MELT AND DEVOLOPED LEAKS. THE LEVEL IN THE GAS TANK WAS LOW ENOUGH THAT NO GAS WAS LEAKING; HOWEVER, THE FUEL LINE WAS SPRAYING GASOLINE ON THE UNDERSIDE OF THE VEHICLE AND ON THE HOT MUFFLER. I CONSIDER MYSELF FORTUNATE THAT I DID NOT HAVE A FIRE IN THE EVENT. I HAVE YET TO REPAIR EITHER OF THESE LEAKS, AND I INTENT TO TAKE PHOTOS PRIOR TO REPAIRS. I DID HAVE TO MOVE THE MUFFLER TO FIND THE LEAKS, AND THAT IS THE ONLY WORK I HAVE DONE AT THIS TIME AND I WILL NOT BE DRIVING THE VEHICLE UNTIL THE LEAKS ARE REPAIRED. THIS COULD BE APPLICABLE TO OTHER GRAND VOYAGERS THAT PASS OVER A LARGE OBJECTS THAT COULD STRIKE THE MUFFLER (I.E ROCKS, CURBS, ETC.) *AK

NHTSA ID

10078994

Incident

Jun 28, 2004

THIS VAN HAS HAD THE FUEL RAIL LEAK RECALL DONE TO IT HOWEVER IT HAS NOW DEVELOPED A LEAK UNDER THEIR FIX. THEIR FIX DOES NOT WORK - I HAVE FUEL RUNNING OUT OVER THE TOP OF THE ENGINE, VALVE COVER AND ONTO THE EXHAUST. I FOUND THIS ON THE RECALL WEB SITE: THE FUEL INJECTION DELIVERY SYSTEM CAN LEAK FUEL FROM SOME OF THE SEALING O-RINGS OR FROM HAIR LINE CRACKS IN THE THERMOSTAT FUEL INJECTION RAIL. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE. 1,163,000 VEHICLES ARE AFFECTED BY THIS RECALL. 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. THEIR FIX DOES NOT WORK, I TOOK GREAT DETAILED PICTURES TO SHOW YOUR ENGINEERS. I JUST DROPPED OFF THE VAN TO GET FIXED, HOWEVER THEIR RECALL FIX DOES NOT WORK. I AM GOING TO DEMAND THAT THEY REPLACE EVERYTHING. *LA

NHTSA ID

10054857

Incident

Jan 23, 2004

Mileage

137,000 mi

THE VAN EXPERIENCED BRAKE FAILURE WHILE DRIVING AT 45 MPH. THE BRAKE PEDAL WENT TO THE FLOOR WHEN IT WAS APPLIED. WHEN THIS OCCURRED, THE VEHICLE FAILED TO STOP IMMEDIATELY, WHICH RESULTED IN EXTENDED STOPPING DISTANCE. THE BRAKE FAILURE WAS CAUSED BY THE REAR BRAKE CYLINDER BURSTING AND LEAKING FLUID. ALSO THERE WAS A GAS SMELL WITHIN THE CABIN OF THE VEHICLE WHEN THE HEAT WAS ON. THE DEALERSHIP INDICATED IT WAS DUE TO A FUEL LEAK WITHIN THE ENGINE COMPARTMENT. *JB

NHTSA ID

10048533

Mileage

141,000 mi

OVER A YEAR AND 1/2, HAD MULTIPLE (AT LEAST 10) INCIDENTS OF VEHICLE STALLING WHILE SLOWING DOWN, AT TURNS OR TRAFFIC LIGHTS. RESULTED IN LOSS OF POWER STEERING, BRAKES, AND TEMPORARY LOSS OF CONTROL ONTO NEXT LANE; LUCKILY, NO ACCIDENTS. MULTIPLE TRIPS TO PLYMOUTH DEALERSHIP, ALL INSPECTIONS AND COSTLY EMPIRICAL REPAIRS ARE FRUITLESS, UNTIL AIS (AUTOMATIC IDLE SPEED) MOTOR REPLACED (THROTTLE BODY CLEANED, ALSO). THE MECHANIC STATED HE HAD SEEN THIS PROBLEM IN HIS OWN PLYMOUTH! THIS FAILURE HAS NOT RECURRED IN THE 3 YEARS SINCE MAKING THE AIS MOTOR THE LIKELY CAUSE OF THE PROBLEM. THIS IS SIMPLY A FOLLOW-UP, HOPEFULLY OF SOME USE TO DRIVERS AND MECHANICS. *LA

NHTSA ID

10041726

Incident

Dec 1, 1999

Mileage

60,000 mi

THERE ARE TWO PROBLEMS WHICH ARE OCCURRING ALL THE TIME: 1. THE VAN SMELLS OF GAS EVERY ONCE IN WHILE. THERE HAVE BEEN A COUPLE OF RECALLS REGARDING THIS MATTER AND THEY HAVE BEEN PERFORMED ON THE VAN. STILL THE FUEL SMELL IS THERE. HAVE WRITTEN TO CHRYSLER, THEY ONLY HAVE ONE ANSWER FOR THIS: YOU HAVE EXCEEDED THE MILEAGE REQUIREMENT FOR WARRANTY. I THINK THIS IS A SAFETY ISSUE AND CHRYSLER SHOULD TAKE CARE OF IT. WHY DO THEY HAVE TO WAIT FOR SOMEBODY TO GET HURT BEFORE THEY WILL PAY UP? PLEASE HELP. 2. WINDSHIELD WIPERS: THESE HAVE BEEN A PROBLEM SINCE I BOUGHT THE VAN. THEY COME ON INTERMITTENTLY. SOMETIMES THEY COME ON WHEN I AM USING TURN SIGNAL, TURNING ON RADIO, OR JUST DRIVING. THEN THERE ARE TIMES WHEN THE VARIOUS SPEEDS STOP WORKING, AND THE WIPERS ONLY WORK AT HIGH SPEEDS. WARRANTY WORK WAS PERFORMED A FEW TIMES DURING WARRANTY PERIOD. SINCE THEN, LAST FALL THE WIPERS STOPPED WORKING COMPLETELY. TOOK IT TO THE DEALER, THEY CHANGED THE BODY MODULE UNIT AND IT COST ME $650 TO FIX IT. IT WORKED FINE FOR A MONTH BUT SINCE THEN THE WIPERS ARE DOING THE SAME THINGS AS MENTIONED EARLIER, EXCEPT THEY HAVEN'T DIED YET. ONCE AGAIN CHRYSLER GIVES ME A STANDARD RESPONSE. THEY KNOW WIPERS ARE A PROBLEM, AND THEY WON'T FIX THEM.*JB

NHTSA ID

10017035

Incident

May 5, 2003

BOUGHT MINI VAN IN 09-14-02, CLOCKSPRING WAS BROKE PAID TO HAVE FIXED 10-12-02, FOUND TWO RECALLS ON VEHICLE THAT WERE NEVER TAKEN CARE OF TIL I PURCHASED SAME THEY RECALLED VANS WITH LESS THEN 70,000 TO FIX CLOCKSPRING BUT I PAID MYSELF AND FEEL THAT IT SHOULD BE INCLUDED IN RECALL BECAUSE IT WAS LIKE THAT ALREADY PEOPLE BUYING USED SHOULD HAVE RIGHTS WHEN IT COMES TO RECALLS I'M SINGLE AND MY VAN COST ME $7,500 RIGHT PAYING OFF NOBODY NEVER CONTACTED CHRYSLER TO LET THEM KNOW THEY NO LONGER HAD VAN SO IT WENT FROM HAND TO HAND TIL I BOUGHT IT THEN I CHECKED RECALLS AND FOUND TWO WITH GAS LINE HAVE THREE KIDSTEENAGERS THAT'S WHY NEED VAN BUT DON'T NEED PROBLEMS REAR SLIDING DOOR ON PASSENGER SIDE WILL NOT OPEN DOOR ONCE LOCKS HAVE BEEN ENGAGED TO OPEN ARE THERE RECALLS ON THIS TOO AND IS IT POSSIBLE FOR COMPANY TO GIVE ME HISTORY ON THIS VAN FOR MY KNOWLEDGE OF PAST OWNERS. THANK YOU GLORIA DT

NHTSA ID

770614

Incident

Sep 25, 2002

THE GAS CAP COVER BROKE WHEN THE NOZZLE HIT IT. THE HOSE WOULD GET COILED UP.TS *JG *JB

NHTSA ID

8023909

Incident

Jan 1, 2001

Mileage

8,000 mi

WHILE FILLING UP THE GASOLINE PUMP TO THE FULL CAPACITY INSIDE OF THE GASOLINE TANK. THE GASOLINE WILL LEAKING FROM THE PUMP THE DEALERSHIP IS AWARE OF THE PROBLEM. TS

NHTSA ID

8021276

Incident

Jan 1, 2001

CONSUMER STATES THAT THERE IS GAS FUEMS IN THE CAB OF VEHICLE. CONSUMER ALSO NOTICED PUDDLE OF GAS UNDER THE CAR. TOOK TO DEALER AND THEY REFUSED TO FIX PROBLEM WITH OUT CHARGING CONSUMER. CONSUMER HAS A PROBLEM WITH THE DEALER NOT RESPONDING. MR

NHTSA ID

8020413

Incident

Mar 3, 2000

NHTSA RECALL 00 V 268 000/MANUFACTURERS RECALL 895 CONCERNING FUEL LEAKAGE: FUEL IS LEAKING FROM THE FUEL RAIL ONTO THE ENGINE. DEALER CONTACTED AND INFORMED CONSUMER THAT VEHICLE WAS NOT COVERED UNDER THAT RECALL DUE TO VIN. *AK *SLC

NHTSA ID

8011591

Incident

Jun 8, 2002

NHTSA RECALL 00V268000/ MANUFACTURER'S RECALL RECALL 895; GAS IS LEAKING UNDERNEATH VEHICLE IN SAME LOCATION FOR FIFTH TIME. VEHICLE WAS RECALLED AND SERVICED ONCE. VEHICLE HAS NEVER BEEN DIAGNOSED TO CORRECT THE ONGOING PROBLEM. DEALER AND MANUFACTURER CONTACTED. PLEASE PROVIDE MORE INFORMATION.*AK

NHTSA ID

8010959

Incident

Jun 3, 2002

NOTICED FUEL LEAKING FROM FUEL TANK. AFTER RESEARCHING INTERNET, ETC. FOUND THAT THERE WAS A RECALL ON THE FUEL RAIL. TOOK TO DEALER FOR RECALL WORK ON FUEL RAIL. RECALL WORK HAD ALREADY BEEN DONE ON O-RING, ETC. AT DEALER, MENTIONED LEAKING GAS TO DEALER. INFORMED THAT VALVE IS LEAKING AND A NEW TANK WOULD BE REQUIRED. AFTER FURTHER RESEARCH FOUND THAT THIS PROBLEM EXISTS FOR MANY, MANY OTHERS! LEAK ONLY OCCURS WHEN TANK IS AT LEAST 3/4 FULL AND VAN IS PARKED WITH THE FRONT ON A DOWNHILL ANGLE! CHRYSLER MUST KNOW OF THE PROBLEM? *AK

NHTSA ID

761641

Incident

May 5, 2002

CHRYSLER KNOWS VERY WELL THAT THERE IS SYSTEM FAILURE IN AIR BAG "CLOCK SPRING" IN THE STEERING WHEEL. NHTSA SHOULD ASK CHRYSLER FOR ONE SIMPLE PIECE OF INFORMATION: HOW MANY DRIVER'S SIDE AIR BAG "CLOCK SPRING" REPLACEMENT PARTS" ARE YOU SELLING? BECAUSE CHRYSLER IS SELLING TENS OF THOUSANDS, IT IS CLEAR TO ANY IDIOT THAT THERE IS A MANUFACTURER'S DEFECT IN THIS IMPORTANT SAFETY DEVICE. CHRYSLER HAS A SIMILAR PROBLEM WITH FUEL TANK SENDER DEVICE. THEY ARE ALL BREAKING. *AK

NHTSA ID

760249

Incident

Oct 1, 1999

RECEIVED RECALL NOTICE #00V268000. CONTACTED DEALERSHIP. WAS INFORMED NO PARTS WERE AVAILABLE TO REPAIR FUEL LEAKAGE RECALL. SERVICE MECHANIC INDICATED IT WAS ON NATIONAL BACK ORDER.*AK

NHTSA ID

8005953

WHEN FILLING UP FUEL TANK COULD SEE A FUEL LEAKAGE ON GROUND. COULD NOT SEE WHERE IT WAS COMING FROM. HAD CONTACTED DEALER. PLEASE PROVIDE MORE INFOMATION.*AK

NHTSA ID

8005642

Incident

Mar 13, 2002

NHTSA RECALL#00-V-268-000. CONSUMER RECEIVED THE RECALL LETTER BEGINNING OF MARCH. DEALER DOESN'T KNOW WHEN THE PART WILL BE AVAILABLE.*AK

NHTSA ID

8005505

Incident

Mar 12, 2002

CONSUMER SMELLED A STRONG ODOR OF GASOLINE. UPON LOOKING UNDERNEATH VEHICLE CONSUMER WAS ABLE TO SEE GASOLINE LEAKING FROM THE FUEL TANK. HAD FUEL TANK REPLACED PRIOR TO RECALL 845, CHRYSLER DECLINED CONSUMERS REQUEST FOR A REFUND. *JG

NHTSA ID

564551

Incident

Aug 1, 2001

CONSUMER HAD FOUND A FUEL LEAKAGE. TOOK VEHICLE TO DEALER, AND THEY FOUND OUT THAT FUEL PUMP HAD TO BE REPLACED. PLEASE PROVIDE MORE INFOMATION.*AK

NHTSA ID

8002755

Incident

Jan 16, 2002

AFTER THE TECHNICIAN BROUGHT TO THE CONSUMER ATTENTION, THAT HE SMELLED GAS, THEY TOOK THE VEHICLE TO DEALER. DEALER DETERMINED THE FUEL TANK VENT LINES WERE FULL OF GAS AND THE REAR GAS TANK VENT AND CANISTER WAS LEAKING, THEREFORE RECOMMENDED A NEW FUEL TANK. BUT THEY DECLINED THE FUEL TANK REPLACEMENT AT THIS TIME. CONSUMER STATED THAT, SINCE THERE HAVE BEEN TWO RECALLS ON THIS FUEL TANK ALREADY, #665 AND#845, CONSUMER FEELS THIS RECENT PROBLEM IS COINCIDENTAL WITH THE RECALL #845, AND THAT THE TANK MIGHT BE DEFECTIVE. *YD

NHTSA ID

564121

Incident

Jul 9, 2001

VERY STRONG GAS ODOR IN VEHICLE. MECHANIC SAID THAT FIRE WAS VERY POSSIBLE SINCE FUEL WAS LEAKING ONTO ENGINE. *AK

NHTSA ID

756334

Incident

Oct 20, 2001