Generations
GS — Third Generation (GS)
1996–2000
3.3L V6, 3.8L V6, 2.5L TD
RT — Fourth Generation (RT)
2001–2007
3.3L V6, 3.8L V6, 2.5L CRD, 2.8L CRD
RT-FL — Fourth Generation Facelift (RT-FL)
2008–2016
2.8L CRD, 2.8L CRD (Euro 5), 3.8L V6
Top issues to watch for
The most serious Chrysler Grand Voyager problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.
Dangerous
Subframe mounting point corrosion (all generations)
The load-bearing structure around suspension component mounting points is prone to severe corrosion on Grand Voyagers, particularly where the rear subframe attaches to the monocoque shell. The large, heavy body combined with UK road salt accelerates corrosion in these critical structural areas. MOT data shows this model fails at 20.4x the fleet average for prescribed area structural defects. When the mounting points weaken, suspension loads can tear through the bodyshell, making the vehicle unsafe to drive.
What happens if ignoredStructural failure of suspension mounting points can cause sudden loss of vehicle control. The rear suspension may separate from the body during braking or cornering. Professional structural welding repair costs £1,500-£3,000 if caught early, but advanced corrosion often renders the vehicle uneconomical to repair.
Independent garage
£1,500–£3,000
Specialist
£2,000–£4,000
Main dealer
£3,000–£5,000
Parts only
£200–£500
Major
Front suspension bush and joint wear (all generations)
Grand Voyagers suffer from rapid deterioration of front suspension bushes and ball joints, with MOT data showing failures at 516.1x the fleet average. The heavy vehicle weight and soft suspension tuning accelerate wear of rubber bushes, particularly the lower arm bushes and anti-roll bar links. This model's high centre of gravity and body roll place additional stress on suspension components compared to conventional cars.
What happens if ignoredWorn suspension components reduce handling precision and braking stability. Failed ball joints can separate completely, causing loss of steering control. Multiple component replacement is often needed due to the interconnected nature of suspension wear patterns.
Independent garage
£400–£800
Specialist
£500–£1,000
Main dealer
£800–£1,500
Parts only
£150–£400
Major
Rear coil spring failure (RT/RT-FL)
The 2.8L diesel variants suffer from rear coil spring fracture at 58.7x the fleet average, particularly on high-mileage examples. The additional weight of the diesel engine over the front axle, combined with the heavy-duty rear springs needed to support typical MPV loading, causes metal fatigue. Spring failure typically occurs at the lower coil where stress concentration is highest.
What happens if ignoredA fractured spring can puncture the tyre or damage adjacent suspension components. The broken spring end can also damage the fuel tank or brake lines. Replacement requires both rear springs to maintain handling balance.
Independent garage
£300–£500
Specialist
£400–£650
Main dealer
£600–£900
Parts only
£120–£250
Major
Parking brake cable and mechanism failure (all generations)
Grand Voyagers show multiple parking brake defects in MOT data - efficiency below minimum requirement (27.2x fleet average), complete inefficiency (26.9x), and single-side inoperative (15.1x). The rear disc parking brake mechanism is prone to seizure due to infrequent use and corrosion. The long cable runs from the console lever to the rear calipers are susceptible to stretching and corrosion, particularly where they route under the vehicle.
What happens if ignoredFailed parking brake prevents the vehicle from passing its MOT test. On slopes, the vehicle may roll unexpectedly when parked. Complete cable replacement is often needed as individual adjustment rarely restores proper operation once cables have stretched.
Independent garage
£200–£400
Specialist
£250–£500
Main dealer
£400–£700
Parts only
£80–£180
1 more known issues tracked
Including wear items, electrical niggles, and generation-specific problems.
MOT failure hotspots
Based on DVSA MOT test data. These are the items where the Chrysler Grand Voyager fails at a significantly higher rate than the average car.
Light unit fault
Lights & Electrics · 20-40k miles
MOT failure rate: 384x the fleet average
Sample: 318 tests
Coil springs broken
Suspension · 40-60k miles
MOT failure rate: 275x the fleet average
Sample: 1,720 tests
Parking brake efficiency less than 50% of the r...
Brakes · 20-40k miles
MOT failure rate: 96x the fleet average
Sample: 508 tests
Power steering fault
Steering · 40-60k miles
MOT failure rate: 80x the fleet average
Sample: 165 tests
Parking brake inoperative on one side
Brakes · 20-40k miles
MOT failure rate: 52x the fleet average
Sample: 329 tests
Lens defective which has no effect on emitted l...
Lights & Electrics · 80-100k miles
MOT failure rate: 49x the fleet average
Sample: 721 tests
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Related
- Chrysler Grand Voyager buyer's guide
- Chrysler Grand Voyager service history check
- Chrysler Grand Voyager service schedule & costs
- Chrysler Grand Voyager MOT failure rates
- Buying a car without service history
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Chrysler Grand Voyager reliability FAQs
What are the most common problems with the Chrysler Grand Voyager?
The Chrysler Grand Voyager has 5 known issues across 2 severity levels. The most serious are: Subframe mounting point corrosion (all generations).
Is the Chrysler Grand Voyager reliable?
The Chrysler Grand Voyager has 1 dangerous and 4 major known issues. Most can be avoided with a thorough pre-purchase check and full service history.
How much does it cost to fix Chrysler Grand Voyager problems?
Repair costs range widely. The most significant issue (Subframe mounting point corrosion (all generations)) costs £1,500–£3,000 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.
Which Chrysler Grand Voyager generation is most reliable?
The GS (1996–2000) has the fewest dangerous issues (1). However, condition and service history matter more than generation — a well-maintained earlier car can be more reliable than a neglected newer one.