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Chrysler Voyager Problems & Known Issues

The most common Chrysler Voyager problems ranked by severity — what to watch for, what it costs to fix, and what happens if you ignore it.

Generations

GS — Third Generation (GS)
1997–2009
2.4L Petrol, 2.5L Diesel, 2.8L Diesel

Top issues to watch for

The most serious Chrysler Voyager problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.

Dangerous
Subframe mounting point structural corrosion
GS1997–200960k–150k miles
The load-bearing structure around subframe and suspension mounting points suffers from severe corrosion on Voyagers, particularly where road salt accumulates in box sections and around mounting brackets. MOT data shows this model fails at 21.4 times the fleet average for prescribed area structural defects. This is a safety-critical failure as mounting point collapse can result in loss of vehicle control. The problem affects all engine variants and worsens with age and mileage.
What happens if ignoredStructural failure around suspension mounting points can cause sudden loss of steering or suspension control. The vehicle becomes unsafe to drive. Repair requires professional assessment and may involve extensive welding or replacement of structural sections costing several thousand pounds.
Independent garage
£800–£2,000
Specialist
£1,000–£2,500
Main dealer
£1,500–£3,500
Parts only
£200–£600
Major
Suspension component excessive wear
GS1997–200960k–150k miles
Suspension pins, bushes, and joints wear excessively on Voyagers, with MOT data showing failure rates 754.5 times higher than the fleet average. The heavy weight of these MPVs combined with soft suspension bushes leads to accelerated wear of front and rear suspension components. Ball joints, anti-roll bar links, and control arm bushes are particularly affected. This wear pattern is consistent across all engine variants.
What happens if ignoredWorn suspension components affect vehicle handling, increase tyre wear, and will fail MOT. Multiple components often need replacement together, with total costs reaching £500-£1,200 for a comprehensive suspension overhaul.
Independent garage
£300–£800
Specialist
£400–£1,000
Main dealer
£600–£1,200
Parts only
£150–£500
Major
General vehicle structure corrosion
GS1997–200980k–150k miles
Body structure corrosion affects vehicle rigidity on Voyagers, with MOT failure rates 12.2 times higher than the fleet average. The problem typically manifests as rust in sills, door frames, tailgate areas, and structural box sections. Poor drainage design allows water accumulation in critical areas, accelerating corrosion. Models from 1997-2009 are all affected as they age beyond 15 years.
What happens if ignoredStructural corrosion reduces vehicle rigidity and compromises safety in a collision. Extensive corrosion will fail MOT and may make the vehicle uneconomical to repair. Professional welding and bodywork can cost £1,500-£4,000 depending on extent.
Independent garage
£500–£2,000
Specialist
£800–£3,000
Main dealer
£1,200–£4,000
Parts only
£200–£800
Major
Handbrake efficiency failure
GS1997–200960k–150k miles
Handbrake systems on Voyagers fail MOT efficiency tests at rates up to 11 times higher than the fleet average. The problem affects both drum brake rear axles and later disc brake setups. Cable stretch, rear brake shoe wear, and handbrake mechanism seizure are common causes. The 2.8L diesel variants show the highest failure rates, likely due to their heavier kerb weight placing additional demands on the parking brake system.
What happens if ignoredInadequate parking brake efficiency will fail MOT and creates a safety risk on slopes. The vehicle may roll away when parked. Repair typically involves rear brake adjustment, cable replacement, or complete rear brake overhaul costing £200-£600.
Independent garage
£150–£400
Specialist
£200–£500
Main dealer
£300–£600
Parts only
£80–£250

1 more known issues tracked

Including wear items, electrical niggles, and generation-specific problems. Check a specific car to see which issues apply to its age and mileage.

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MOT failure hotspots

Based on DVSA MOT test data. These are the items where the Chrysler Voyager fails at a significantly higher rate than the average car.

Coil springs broken
Suspension · 60-80k miles
MOT failure rate: 724x the fleet average
Sample: 798 tests
ABS fault
Brakes · 60-80k miles
MOT failure rate: 27x the fleet average
Sample: 485 tests
Anti-roll bar links worn
Suspension · 60-80k miles
MOT failure rate: 16x the fleet average
Sample: 514 tests
Parking brake efficiency less than 50% of the r...
Brakes · 60-80k miles
MOT failure rate: 14x the fleet average
Sample: 338 tests
Steering rack wear
Steering · 120-150k miles
MOT failure rate: 14x the fleet average
Sample: 1,171 tests
Vehicle structure corroded to the extent that t...
Bodywork · 80-100k miles
MOT failure rate: 12x the fleet average
Sample: 249 tests

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Related

Chrysler Voyager reliability FAQs

What are the most common problems with the Chrysler Voyager?

The Chrysler Voyager has 5 known issues across 3 severity levels. The most serious are: Subframe mounting point structural corrosion.

Is the Chrysler Voyager reliable?

The Chrysler Voyager has 1 dangerous and 3 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 Voyager problems?

Repair costs range widely. The most significant issue (Subframe mounting point structural corrosion) costs £800–£2,000 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.