1999 Plymouth Voyager Brakes Problems

I HAVE SEEN ON CERTAIN CHRYSLER MODELS, ESPECIALLY MINIVANS, WITH THE 2-PIN FLOATING CALIPER DESIGN THAT THE SURFACE OF THE STEERING KNUCKLE WHERE THE BRAKE PADS RIDE WEARS AWAY AND CAN CAUSE THE AFFECTED WHEEL TO LOCK UP EITHER DURING A STOP OR AFTER THE BRAKE PEDAL IS RELEASED. THIS IS CAUSED BY THE BRAKE PADS WEDGING IN THE GROOVE. IF THIS WERE TO HAPPEN DURING A BRAKE APPLICATION, THE VEHICLE COULD VEER INTO ONCOMING TRAFFIC, CAUSING AN ACCIDENT. I HAVE ALSO NOTICED THAT THE MOUNTING DESIGN (IE: BOLTS AND SLIDE PINS,) IS FLAWED. THE BOLTS ARE TOO SHORT AND DO NOT MAKE ENOUGH CONTACT WITH THE THREADS, ESPECIALLY AFTER ROUTINE BRAKE MAINTENANCE THE HOLES CAN BECOME STRIPPED. CHRYSLER RECOMMENDS A TORQUE OF 119 IN/LBS OR 16 FT/LBS (SOURCE: ALLDATA 2011 LLC,) ALTHOUGH WHEN TORQUED TO SPECIFICATION, THE BOLT THREADS STRIP OUT. IF THE BOLTS WERE TO BE LOOSE OR ULTIMATELY FALL OFF THE VEHICLE, THE CALIPER WILL RIDE ON THE INSIDE OF THE WHEEL, MAKING NOISE OR LOCKING THE WHEEL DURING ANY DRIVING MANEUVER; WHICH CAN LEAD TO A CRASH. CORRECTION TO THE FAILING KNUCKLE IS SIMPLE IF FOUND EARLY ENOUGH. THE EDGES CAN BE GROUND DOWN TO ALLOW THE PADS TO MOVE SMOOTHLY, SHIMS CAN BE ADDED TO COMPENSATE FOR THE REMOVED MATERIAL AND A DECENT HIGH-TEMPERATURE BRAKE GREASE SHOULD BE USED ON THE SLIDING SURFACE. CORRECTION TO THE CALIPER MOUNTING HARDWARE IS THREAD REPAIR WITH A HELICOIL SET FOR 9MM BOLTS. IT WOULD BE NICE TO HAVE EXTENDED BOLTS AVAILABLE (METRIC GRADE 10.9,) FROM THE MANUFACTURER. TOO OFTEN THAN NOT I HAVE SEEN THESE PROBLEMS WHERE BRAKE MAINTENANCE IS ALMOST/OVER DUE. *TR

NHTSA ID

10402256

Incident

May 20, 2011

Mileage

100,000 mi

TL*THE CONTACT OWNS A 1999 PLYMOUTH VOYAGER. WHILE DRIVING APPROXIMATELY 60 MPH, HE ATTEMPTED TO ENGAGE THE BRAKE PEDAL AND NOTICED THAT THE BRAKE PEDAL WAS NON-RESPONSIVE. HE DROVE THE VEHICLE TO HIS RESIDENCE AND NOTIFIED A REPAIR SHOP. THE VEHICLE WAS TOWED TO THE REPAIR SHOP AND A MECHANIC STATED THAT THE BRAKE LINE FAILED. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 85,500. **10/14/09 CW ADDED ADDITIONAL INFO. UPDATED 10/14/09.*JB UPDATED 10/29/09 *CN UPDATED 10/29/09

NHTSA ID

10286300

Incident

Sep 30, 2009

Mileage

8,500 mi

TL*THE CONTACT OWNS A 1999 CHRYSLER VOYAGER. WHILE DRIVING BETWEEN 5-10 MPH, THE VEHICLE WOULD NOT STOP. THE FAILURE HAS BEEN OCCURRING EVERYDAY SINCE THE VEHICLE WAS PURCHASED. THE BRAKES HAVE BEEN INSPECTED EACH YEAR. THE CONTACT STATED THAT THE BRAKES ARE NOT GRABBING. THE CURRENT MILEAGE WAS 204,000 AND FAILURE MILEAGE WAS 28.

NHTSA ID

10227069

Incident

May 8, 2008

Mileage

28 mi

TL*THE CONTACT OWNS A 1999 PLYMOUTH VOYAGER. WHILE DRIVING 65 MPH, THE BRAKE LINE FAILED. THE DEALER STATED THAT THE ENTIRE BRAKE LINE WAS BADLY CORRODED. THE CONTACT STATED THAT IT WAS A CATASTROPHIC FAILURE THAT SHOULD HAVE NEVER OCCURRED. THE CURRENT AND FAILURE MILEAGES WERE 104,000. UPDATED 02-14-08. *KB

NHTSA ID

10215781

Incident

Jan 22, 2008

Mileage

104,000 mi

DT*: THE CONTACT STATED WHILE DRIVING 50MPH BRAKE PRESSURE WAS APPLIED AND THE VEHICLE HAD AN INCREASED STOPPING DISTANCE. THE VEHICLE WAS INSPECTED BY AN INDEPENDENT REPAIR SHOP. THE MECHANIC SUGGESTED REPLACING THE ANTILOCK BRAKE BOOSTER ASSEMBLY. ALTHOUGH THE PROBLEM PERSISTED, NO REPAIRS WERE MADE.

NHTSA ID

10149938

Incident

Jan 28, 2006

Mileage

66,000 mi

DT: THE CONTACT COMPLAINED ABOUT BRAKE PROBLEMS. THERE HAVE BEEN THREE ACCIDENTS AS A RESULT OF THE BRAKES NOT COMPLETELY STOPPING THE VEHICLE. WHEN APPLYING THE BRAKES THE VEHICLE LURCHED FORWARD. THE VEHICLE HAS NOT BEEN INSPECTED TO DETERMINE THE CAUSE OF THE BRAKE PROBLEMS. *AK

NHTSA ID

10140334

Incident

Jan 27, 2000

Mileage

1,800 mi

WHEN APPLYING BRAKES IN A SUDDEN/EMERGENCY STOP VEHICLE EXPERIENCED EXTENDED STOPPING DISTANCE. VEHICLE HAD BEEN TO DEALER ON THREE OCCASIONS, AND THEY WERE UNABLE TO DUPLICATE THE PROBLEM.*AK

NHTSA ID

10101942

Incident

Dec 12, 2000

Mileage

27,000 mi

WHILE DRIVING 72 MPH, THE DRIVER'S SEAT BACK COLLAPSED BACKWARD, ALMOST HITTING THE FLOOR, BECAUSE BOTH REAR SEATS WERE REMOVED TO CARRY CARGO. THE DRIVER BARELY KEPT A GRIP ON THE STEERING AND PULLED HIMSELF UP AND WAS ABLE TO MAINTAIN CONTROL OF THE VAN. THE DRIVER REMOVED THE SIDE PANEL OF THE SEAT AND NOTICED THAT A PLASTIC PIECE INSIDE THE PANEL HAD BROKE. THE DEALERSHIP HAS BEEN CONTACTED. THE CAUSE OF PIECE BREAKING HAS YET TO DETERMINED. THE FOLLOWING DAY WHEN THE EMERGENCY PARKING BRAKES WAS DISENGAGED, THE LEVER BROKE OFF IN THE CONSUMER'S HAND. *JB

NHTSA ID

10097400

Incident

Oct 20, 2004

Mileage

194,000 mi

I HAVE HAD THE BRAKES WORKED ON 4 DIFFERENT OCCASIONS NOW. CONTINUAL LOSS OF BRAKE FLUID. WHEN MAKING A LEFT HAND TURN BRAKE LIGHT WILL COME ON. MASTER CYLINDER HAS BEEN REPLACED ALL BRAKE SHOES HAVE BEEN REPLACE, ALONG WITH CALIPERS. TWO WEEKS PASSED AND BRAKE LIGHT STARTING TO COME ON AGAIN, AND THERE WAS FLUID LOSS. TOOK VAN BACK IN APPROX 3 WEEKS AGO TO BE WORKED ON, AND BRAKE LIGHT IS NOW COMING ON AGAIN, AND STAYING ON LONGER EACH TIME.*AK

NHTSA ID

10088428

Incident

Aug 23, 2004

Mileage

32,000 mi

WHILE APPLYING THE BRAKES BRAKE PEDAL WENT DOWN TO THE FLOOR, CAUSING A LOSS OF BRAKE POWER. VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT THE MASTER CYLINDER NEEDED TO BE REPLACED DUE TO WORN OUT PARTS. *AK

NHTSA ID

10073914

Incident

May 19, 2004

THE INSIDE OF EACH FRONT BRAKE ROTOR WAS PITTED. THE ROTORS WERE ORIGINAL EQUIPMENT FOR THE CAR AND WERE REPLACED WITH AFTER MARKET ROTORS. *JB *CB *JB

NHTSA ID

10020433

Mileage

75,000 mi

IT HAS BEEN NOTICED THAT THE BRAKES (THE WHOLE SYSTEM) HAVE TO BE REPLACED EVERY THREE MONTHS. THE LAST TIME THE BRAKES HAD TO BE REPLACED WAS ON 4/28/2003. *AK

NHTSA ID

10024862

PREMATURE CORROSION OF BRAKE LINES. TWO BRAKE LINES LEADING TO THE REAR BRAKES RUSTED AT JUNCTIONS BETWEEN THE HARD TUBING AND FLEXIBLE TUBING. BOTH CORRODED WITH THE SAME PATTERN AND ONLY AT THE ABOVE MENTIONED LOCATION. INDICATIVE OF MATERIAL INCOMPATIBILITY - FAILURE TO ENGINEER THE PART PROPERLY. RUSTED PART FAILED COMPLETELY AND WITHOUT WARNING. COULD HAVE CAUSED AN ACCIDENT IF THE VEHICLE WAS MOVING FAST AND NEEDED TO BRAKE HARD. THE GAS TANK HAD TO BE REMOVED TO REPLACE THE FAULTY BRAKE LINES. THEY WERE, THEREFORE, VERY EXPENSIVE TO REPLACE. *NLM

NHTSA ID

10023409

Incident

Apr 7, 2003

Mileage

44,500 mi

$5,975.00 - IN THE LAST 16 MONTHS THE 1999 PLYMOUTH VOYAGER VAN I PURCHASED AT COURTESY CHRYSLER HAS BEEN IN THE SHOP OVER 18 TIMES, OFTEN FOR THE SAME PROBLEMS. I HAVE HAD TO BUY 6 NEW TIMES AND 3 NEW BATTERIES. ON AVERAGE, I HAVE ADDED BETWEEN 3 AND 4 QUARTS OF OIL EVERY MONTH AND NEW COOLANT EVERY 3 MONTHS (IT OVER HEATS A LOT). I HAVE SUFFERED VERBAL AND MENTAL ABUSE FROM THE PERSONNEL AT COURTESY CHRYSLER TO THE POINT WHERE I HAD TO JUMP OUT OF MY MOVING VAN AS MY PERSONAL SERVICE ADVISOR WAS BERATING ME AND TOLD ME THAT THERE WAS NOTHING WRONG WITH MY VAN, THE BRAKES, THE ENGINE, ETC., DURING A TEST DRIVE. WHEN I OPENED THE DOOR TO JUMP OUT HE STEPPED ON THE BRAKES...AND THEY DID NOT WORK! MIND YOU, THEY HAD MY VEHICLE IN THEIR SHOP FOR THE LAST TWO DAYS TO REPAIR THE BRAKES AND MY PERSONAL SERVICE ADVISOR KEPT SAYING THAT THE VAN WAS FINE! AFTER GIVING ME A BRAND NEW 2002 CHRYSLER MINIVAN, THEY SAID THAT MY VAN WOULD BE READY THE NEXT AFTERNOON FOR PICK-UP AND IF THERE WERE ANY PROBLEMS, THEY WOULD CONTACT ME.*AK

NHTSA ID

761819

BRAKES HAVE BEEN REPLACED TWICE SINCE VEHICLE WAS PURCHASED. STOPPING DISTANCE HAS INCREASED, AND THERE IS A NOISE THAT COMES FROM BRAKES. CONTACTED DEALER, AND DEALER CANNOT FIGURE OUT WHAT CAUSED IT. *AK

NHTSA ID

8003102

Incident

Jan 1, 2000

VEHICLE IN REVERSE GEAR WITH FOOT ON THE BRAKE WHEN IT SUDDENLY ACCELERATED BACKWARDS. VEHICLE WAS STOPPED BY TWO CHAIN LINK FENCES. DEALER WAS NOTIFIED AND COULDN'T FIND CAUSE. *AK

NHTSA ID

8002813

Incident

Dec 9, 2001

WHILE ATTEMPTING TO MAKE A SUDDEN STOP WHILE TRAVELING 25 MPH ON DAMP ROAD CONDITIONS, ANTI-LOCKING BRAKE SYSTEM FAILED, CAUSING PEDAL TO GO TO THE FLOOR. PARKING BRAKE HAD TO BE ENGAGED IN ORDER TO STOP VEHICLE. PLEASE PROVIDE FURTHER DETAILS.*AK

NHTSA ID

8000718

Incident

Dec 13, 2001

WHEN TURNING TO THE LEFT, THE ABS BRAKE LIGHT COMES ON UNTIL VEHICLE IS TURNED TO THE RIGHT. WHEN THIS HAPPENS, IT GOES OFF. HAD TAKEN VEHICLE TO DEALER, AND MECHANIC PLACED IT ON DIAGNOSTIC MACHINE AND NOTHING WAS FOUND. PROBLEM IS GETTING WORSE. ABS BRAKE LIGHT HAS REMAINED STEADILY ON.*AK *JB

NHTSA ID

897735

Incident

Jul 9, 2001

CONSUMER PARKED VEHICLE AND NOTICED SMOKE AND HEARD A CRACKLING NOISE, VEHICLE EXPERIENCED FIRE IN ENGINE AREA, CLAIM 35-R110-141. *SLC

NHTSA ID

6900682

Incident

Jul 16, 2001

WHENEVER AIR CONDITIONER WAS IN USE BRAKE LIGHT ILLUMINATED ON THE DASH. CONSUMER HAS YET TO CONTACT DEALER. PLEASE PROVIDE FURTHUR DETAILS. *AK

NHTSA ID

890450

THERE WAS A NOISE COMING FROM THE FRONT RIGHT OF VEHICLE. DEALERSHIP INFORMED HIM THEY NEEDED TO REPLACE FRONT BRAKES AND ROTATE ROTORS AT 22,000 MILES. A BRAKE SPECIALIST INFORMED HIM THAT REAR RIGHT CYLINDER WAS LEAKING FLUID WITH LESS THAN 23,000 MILES ON VEHICLE. PLEASE PROVIDE ANY ADDITIONAL INFORMATION/ATTACHMENTS. *NOTE, CONSUMER SPOKE WITH ANOTHER CONSUMER WHO WAS EXPERIENCING SAME PROBLEM WHILE AT DEALERSHIP.*AK

NHTSA ID

886790

Incident

Mar 26, 2001

FRONT END GOES THROUGH TOO MANY BRAKES. *AK

NHTSA ID

738508

Incident

Dec 15, 1999

I HAVE LOST MY BRAKES TWICE, WITHOUT WARNING, MASTER CYLINDER KEEPS FAILING.*AK

NHTSA ID

732775

Incident

Sep 24, 2000

WITH ALMOST 24,000 MILES ON MY VEHICLE, WITHOUT ANY WARNING AT ALL, MY BRAKES BEGAN GRINDING. I DROVE THE VEHICLE HOME AND CALLED TO BRING IT IN FOR SERVICE. THE VEHICLE HAD BEEN FINE THE REST OF THE DAY AND WEEKS PREVIOUS. MY HUSBAND LOOKED AT CAR AND BRAKES WERE METAL TO METAL--THIS WAS ON A WEDNESDAY. NO DEALER HAD APPT TILL MONDAY. I HAD TO BE EXTREMELY AGGRESSIVE TO GET A NEXT DAY APPT. HAD IT REPAIRED NEXT DAY AT RAMSEY CHRSYLER IN NJ. I'M CONCERNED THAT THERE WOULD HAVE BEEN A FAILURE OF BRAKES HAD I NOT BEEN SMART ENOUGH TO STOP DRIVING IT (THERE ARE MANY PEOPLE WHO WOULDN'T REALIZE IT WAS A MAJOR PROBLEM). I USUALLY HAVE MY 2 YEAR OLD IN THE CAR AND WAS QUITE UPSET THAT WITHOUT ANY WARNING SENSOR OR LIGHT THE BRAKES WERE METAL TO METAL.

NHTSA ID

727185

WHEN PRESSING ON THE BRAKES VAN WOULD JERK BACK AND FORTH. ALSO, BACK DOOR LATCH IS GETTING HARD TO OPEN.*AK

NHTSA ID

864975

Incident

Jul 1, 2000