Workshop Manuals Factory service & repair Plymouth

Plymouth common faults and how to fix them

Faults that are well known on Plymouth models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Plymouth Neon head gasket: 2.0 coolant and oil leaks and the multi-layer steel gasket (1995–2000)

Symptoms

Typical signs of a leaking head gasket are coolant or oil seeping from the joint between the cylinder head and block, a slowly falling coolant level, and in worse cases overheating or white smoke. It affects the 2.0 SOHC and DOHC engines in the Neon and Breeze.

Cause

A Chrysler bulletin covers multi-layer steel (MLS) head gaskets for the 1995–2000 Neon, Breeze, Cirrus, Stratus and Sebring convertible, and 1995–1999 Avenger, Sebring and Talon, with the 2.0 SOHC or DOHC (non-turbo) or 2.4 engines. Chrysler introduced the MLS gasket, which it describes as giving superior sealing, as a running change in 1999 production. Earlier engines were built with the previous gasket design.

Fix

Confirm the gasket is leaking with a cooling system pressure test and a check for combustion gases in the coolant. When replacing a Plymouth Neon head gasket, fit the MLS gasket and follow the bulletin's installation procedure. Check the head for flatness while it is off, and use new head bolts if the manual calls for them.

Repair instructions on this site

Sources: Chrysler technical service bulletin, MLS head gasket installation procedures.

Plymouth Breeze recall: lower control arm ball joint separation

Symptoms

Usually nothing until the joint is badly worn; a knock from the front suspension or play in a front wheel may be the first sign. In the worst case the ball joint separates and steering control is lost.

Cause

NHTSA recall 97V201000 covers certain Plymouth Breeze models. The lower control arm ball joint can lose its lubrication, wear and separate. The recall checks the joint's end housing cover seal and rubber boot, which keep the lubricant in.

Fix

Check with a Chrysler dealer that the recall has been done. The remedy tests the ball joint end housing cover seal for leaks with a high-pressure air tester and inspects the rubber boot; if either has failed, the lower control arm is replaced, as the Plymouth Breeze ball joint recall describes. On any Breeze, check the boots and joints for play at each service.

Repair instructions on this site

Sources: NHTSA recall 97V201000.

Plymouth Voyager transmission: 41TE delayed engagement (1989–1995)

Symptoms

After starting, the automatic gearbox takes a moment to engage drive or reverse, sometimes with a fault code stored. It affects the 41TE four-speed automatic in the Voyager, Grand Voyager, Acclaim and Sundance.

Cause

Chrysler bulletin 21-07-98 covers delayed engagement on the 41TE and 42LE in many Chrysler group cars and minivans, including the 1989–1995 Voyager and Acclaim and the 1992–1994 Sundance. It lists known causes that were hard to diagnose in the field, such as loss of fluid prime. Where code 35 is set and there is no other cause such as a low fluid level or a badly fitted filter, the bulletin says the oil pump needs replacing.

Fix

Check the fluid level and condition first, using the correct fluid, and confirm the filter is fitted properly. Then use the Plymouth Voyager transmission bulletin's table to match the symptoms and codes to the repair. After any repair, run the quick-learn procedure so the gearbox relearns its clutch volumes.

Repair instructions on this site

Sources: Chrysler technical service bulletin 21-07-98.

Plymouth oil leak: 2.2 and 2.5 rocker cover gasket recall (1989–1990)

Symptoms

Oil leaking from the cylinder head (rocker) cover gasket onto the engine and exhaust, often with a smell of burning oil.

Cause

Chrysler safety recall 467 covers 1989 and early 1990 cars and vans with the 2.2 and 2.5 fuel-injected, non-turbo engines, including the Plymouth Acclaim, Reliant, Horizon, Sundance and Voyager. The cylinder head cover gasket could move out of place and let engine oil leak. Depending on where and how much it leaked, an engine compartment fire could result.

Fix

Check with a Chrysler dealer that recall 467 has been done; the remedy fits a revised cylinder head cover with a silicone rubber gasket. On any of these engines, clean off old oil and fix leaks promptly, as oil on the exhaust is a fire risk. The Plymouth rocker cover recall lists the models covered.

Repair instructions on this site

Sources: Chrysler safety recall 467 (March 1990).