2002 Chrysler Voyager Recalls, Problems & Maintenance

The 2002 Chrysler Voyager has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Front suspension sway bar bushing and ball joint wear.” Chrysler's Oil Change Indicator tracks engine load and duty cycle, then messages when oil life is used up — capped at 10,000 miles or 12 months, whichever comes first. The 3.6L Pentastar V6 (300, Pacifica, Town & Country, Voyager) is long-interval by design: spark plugs at 100,000 miles and no timing belt. Minivans in family duty count as 'severe service' more often than owners think — frequent short trips shorten the oil indicator's countdown, and that's the system working correctly.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Chrysler Voyager.

Reported to NHTSA

Front suspension sway bar bushing and ball joint wear

SUSPENSION

5 NHTSA complaints · 2003-08 → 2007-04

“CLUNKING FROM FRONT SUSPENSION AND DECREASE IN VEHICLE STABILITY. DIAGNOSED AS FAILURE OF SWAY BAR BUSING”
— Owner report, NHTSA ODI #10188489
“TL* - THE CONTACT RECEIVED A SAFETY RECALL 2W125384-F23 FOR LOWER BALL JOINTS FROM DAIMLER CHRYSLER. THE CONTACT STATED THAT IT HAS BEEN OVER A MONTH AND CHRYSLER HAS TOLD HER THAT THEY DON'T HAVE THE PARTS”
— Owner report, NHTSA ODI #10176661
“FRAME/STRUCTURE OVER THE RIGHT SIDE STRUT HAS RUSTED. THIS COULD RESULT IN STRUT FAILURE AND VEHICLE LOSING STEERING”
— Owner report, NHTSA ODI #10022925

Read all complaints on NHTSA →

Rear GEN3 seat belt buckle unlatching

SEAT BELTS

5 NHTSA complaints · 2002-03 → 2003-08

“PLEASE RECALL THE CHRYSLER GEN3 SEATBELTS. THEY HAVE BEEN TESTED BY INDEPENDANT ORGANIZATIONS AND HAVE BEEN SHOWN TO UNLATCH DURING TESTS. THE GEN3 SEATBELT DESIGN FAILS THE STANDARD AUTO INDUSTRY TEST”
— Owner report, NHTSA ODI #759457
“ON 2 SEPARATE OCCASIONS, WE HAVE FOUND OUR INFANT DAUGHTER'S SEAT BELT UNBUCKLED WITH NO EXPLANATION AS TO THE CAUSE SINCE WE ARE OBSESSIVE ABOUT SEAT-BELT USE”
— Owner report, NHTSA ODI #10016564
“SEATBELT LIGHT CAME ON. VEHICLE WAS TAKEN TO DEALER 7 TIMES BEFORE SEATBELT WAS REPLACED”
— Owner report, NHTSA ODI #8014884

Read all complaints on NHTSA →

Fuel rail leak with fire risk

FUEL/PROPULSION SYSTEM

10 NHTSA complaints · 2015-10 → 2023-02

“TL* THE CONTACT OWNS A 2002 CHRYSLER VOYAGER. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT NOTICED FUEL FUMES IN THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL RAIL NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #10786712
“WANT CAR INSPECTED FOR DEFECTS. FUEL RAIL LEAKING GAS ONTO INTERIOR AND EXTERIOR OF VEHICLE. GAS FUMES COME IN THROUGH VENTS, INTOXICATING CANNOT USE VEHICLE. MECHANIC STATED,"CAN GO ON FIRE!" CAN CATCH ON FIRE OR IGNITE FROM CIGARETTE OR MATCH OUTSIDE VEHICLE CANNOT FIX”
— Owner report, NHTSA ODI #11151970
“I had over 40 Complaints with NHTSA. FUEL LEAK - vehicle can go on fire,fumes intoxicating in vehicle through vents..Every mechanic," VEHICLE CAN GO ON FIRE."”
— Owner report, NHTSA ODI #11502142

Read all complaints on NHTSA →

Service brake failure from fluid loss

SERVICE BRAKES, HYDRAULIC

8 NHTSA complaints · 2002-08 → 2016-01

“TL* THE CONTACT OWNS A 2002 CHRYSLER VOYAGER. THE CONTACT STATED THAT THE VEHICLE'S BRAKE SEAL FRACTURED AND CAUSED THE BRAKES NOT TO WORK PROPERLY. THE VEHICLE WAS TAKEN TO A DEALER TO BE DIAGNOSED AND REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE FAILURE”
— Owner report, NHTSA ODI #10820441
“TL*THE CONTACT OWNS A 2002 CHRYSLER VOYAGER. WHILE DRIVING APPROXIMATELY 60 MPH, THE BRAKE SYSTEM SPONTANEOUSLY FAILED. THE CONTACT HAD TO APPLY TREMENDOUS PRESSURE TO THE BRAKE PEDAL IN ORDER FOR THE BRAKES TO FUNCTION”
— Owner report, NHTSA ODI #10232302
“WHEN BRAKES ARE APPLIED PEDAL HAS A DELAY IN RESPONSE FROM THE SYSTEM. OWNER STATES THAT BRAKES WOULD EITHER LOCK UP OR NOT RESPOND QUICKLY ENOUGHT TO PREVENT LOCKING UP”
— Owner report, NHTSA ODI #8016642

Read all complaints on NHTSA →

Airbag warning light illumination and clock spring failure

AIR BAGS

19 NHTSA complaints · 2002-05 → 2018-11

“TAKATA RECALL I OWN A 2002 CHRYSLER VOYAGER MINIVAN. AT ABOUT 85,000 MILES I NOTICED THE AIRBAG LIGHT ON THE DASHBOARD WAS COMING ON SPORADICALLY. EVENTUALLY IT STARTED REMAINING ON ALL THE TIME FROM THE MOMENT I STARTED THE IGNITION”
— Owner report, NHTSA ODI #11091057
“THE CLOCK SPRING IN MY VOYAGER IS FAILING. THE HORN NO LONGER WORKS AND THE AIRBAG LIGHT GOES ON AND OFF INTERMITTENTLY. CHRYSLER HAS RECALLED THIS MINIVAN BEFORE BUT DID NOT EXTEND THE RECALL TO THE 2002 YEAR”
— Owner report, NHTSA ODI #10242243
“CONSUMER STATES HAVING PROBLEMS WITH AIR BAG LIGHT CONSTANTLY ILLUMINATING. DEALER HAS CORRECTED 5 TIMES, BUT PROBLEM CONTINUES TO OCCUR”
— Owner report, NHTSA ODI #10004428

Read all complaints on NHTSA →

Airbag deployment failure in a collision

AIR BAGS

7 NHTSA complaints · 2003-01 → 2005-03

“WHILE DRIVING 30 MPH, THE VEHICLE WAS INVOLVED IN A FRONTAL COLLISION. BOTH FRONTAL AIR BAGS FAILED TO DEPLOY. THERE WERE NO INJURIES. THE VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION”
— Owner report, NHTSA ODI #10087973
“WHILE DRIVING 20 MPH DUAL AIRBAGS DEPLOYED INADVERTENTLY. DRIVER SUSTAINED SEVERE NECK INJURIES”
— Owner report, NHTSA ODI #10063492
“WHILE TRAVELING ABOUT 55MPH ON THE HIGHWAY ANOTHER VEHICLE VEERED INTO THE CONSUMER AND THE DRIVER SIDE AIR BAGS DIDN'T DEPLOY”
— Owner report, NHTSA ODI #10004467

Read all complaints on NHTSA →

Power steering hose and rack-and-pinion failure

STEERING

10 NHTSA complaints · 2003-01 → 2008-05

“THE VEHICLE (CHRYSLER VOYAGER 2002) HAD A TOTAL FAILURE OF ITS POWER STEERING AND REQUIRES COMPLETE REPLACEMENT OF STEERING RACK. THE VEHICLE IS STILL OUT OF SERVICE EVEN AFTER 11 DAYS”
— Owner report, NHTSA ODI #10003344
“POWER STEERING HOSE "BLEW OUT" WHILE DRIVING, CAUSING LOSS OF POWER STEERING FLUID AND FUNCTIONS”
— Owner report, NHTSA ODI #10022619
“2002 CHRYSLER VOYAGER TIE ROD FELL OFF OF THE RACK AND PINION WHILE THE VEHICLE WAS IN MOTION”
— Owner report, NHTSA ODI #10133432

Read all complaints on NHTSA →

Automatic transmission failure and gear slippage

POWER TRAIN

10 NHTSA complaints · 2002-07 → 2008-07

“OWNED 2002CHRYSLER MINI VAN..HAD TO DEPRESS THE BRAKE EXTRA HARD FOR IT TO ENGAGE IN PARK AND IF I'M IN A HURRY AND DIDN'T STEP ON THE BRAKE EXTRA HARD IT WON'T STAY IN PARK”
— Owner report, NHTSA ODI #10195537
“DT*: THE CONTACT STATED WHILE DRIVING 65 MPH THE ENGINE LIGHT ILLUMINATED. THE VEHICLE STARTED TO JERK AND THEN STALLED. THE VEHICLE WAS TOWED TO THE DEALERSHIP”
— Owner report, NHTSA ODI #10157377
“CONSUMER TOOK VEHICLE TO DEALER ON 5 SEPARATE OCCASSIONS REGARDING TRANSMISSION FAILURE. TRANSMISSION WAS SERVICED AND ADJUSTED. HOWEVER, THE DEFECT RECURREDE”
— Owner report, NHTSA ODI #10099883

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (Oil Change Indicator)

Every 10,000 mi

Change oil when the indicator message appears — never beyond 10,000 miles or 12 months. Pentastar 3.6L uses 0W-20; PT Cruiser's 2.4L uses 5W-30. Short-trip city driving will trigger the indicator well before 10,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 8,000 mi

Rotate every 8,000 miles or at every oil change. Front-heavy minivans (Pacifica, Voyager) chew front tires quickly without rotation.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect pads, rotors, and parking brake at every oil change. Loaded minivans and the heavy 300 wear rear pads faster than expected — check both axles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Timing Belt (2.4L PT Cruiser)

Every 100,000 mi

PT Cruiser's 2.4L is a timing-belt engine: replace around 100,000 miles (check your manual's exact interval for the year). Do the water pump and tensioner in the same job — the labor overlaps almost entirely.

Estimated cost — typical U.S. ranges

Dealer

~$935–$1175

Shop

~$655–$825

DIY

Pro only

On interference engines, a snapped belt destroys valves. Worth doing on schedule. Bundle water pump + tensioner — labor is already there.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Automatic Transmission Fluid

Every 60,000 mi

Minivans (62TE six-speed): ATF+4 service every 60,000 miles under family duty. 300 with the ZF/TorqueFlite 8-speed: Chrysler lists no normal-service interval, but specialists recommend fluid service around 60,000-100,000 miles. ATF+4 or the specified 8-speed fluid only.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Spark Plugs

Every 100,000 mi

Pentastar 3.6L: iridium plugs at 100,000 miles. PT Cruiser 2.4L: roughly every 30,000 miles with conventional plugs — check the manual for your year.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Air Filter

Every 30,000 mi

Replace every 30,000 miles. On the Pentastar it's a quick top-of-engine job; inspect sooner in dusty climates.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Serpentine Belt

Every 60,000 mi

Inspect from 60,000 miles and replace on evidence of cracking or glazing. A failed belt on the Pentastar takes the water pump drive with it — don't run it to destruction.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace every 20,000 miles — behind the glovebox on Pacifica, Voyager, and 300. Family-hauler duty (pets, gravel school lots) argues for yearly.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Coolant Replacement (OAT)

Every 100,000 mi

Stellantis OAT coolant: first replacement at 10 years or 150,000 miles per the schedule; many shops suggest refreshing by 100,000 miles. Use OAT-compatible coolant only — mixing types gels the system.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Battery Test & Service

Every 25,000 mi

Test annually once the battery passes 3 years old. Pacifica's stop-start system uses a pricier AGM or dual-battery setup — weak batteries throw confusing electrical faults first.

Estimated cost — typical U.S. ranges

Dealer

~$225–$390

Shop

~$160–$280

DIY

~$130–$250

Most auto-parts stores test and install batteries free with purchase. Skip the dealer markup.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

No occupant deaths in FARS 1990–2024 crashes are on record for this year and model. That is the census answer for the window, and it says nothing more than that.

Crash years covered: 1990–2024 Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

6

complaints mentioning a crash

1

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Chrysler Voyager reflects Chrysler's published service intervals and the Oil Change Indicator System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.