[Smitri]

Hello,

I'm about to turn 30 in a couple months and have had this 91 Mustang (2.3 L manual trans) since I was 18. Four years ago the engine started to chug and after having the ignition coils, timing belt and some other things replaced with an auto major friend of mine at the university he determined that it has to be a rod knock. My father came down a couple weeks later and confirmed it.

I have driven it three times since then, mainly to move from one location around campus to another and it has now been sitting for over a year and a half. The other times it started right up, maybe a second turn of the key if anything.

Long story short I am hoping to have enough money to fix this up and I was wondering what those on this site think I should do. I can have the rod taken out, heads redone, etc. to rebuild this engine or get another one? From a couple people I talked to they recommend just getting a new rebuilt engine in it.

In addition, I was wondering what cost I would be looking at approximately for the job to be done? I was estimating about $1500 for a 2.3 and more like $3500 for a 5.0 since I assume the trans and other things will need to be replaced.

On another note, there is some front end damage from a hit and run someone did years ago which would result in a front bumper and probably some metal work done on the front end along with my 1/4 panels and a paint job. Any estimates on that as well?

Thanks in advance for any help you can provide.


Rich

[Mustanq]

Wow you sound like just like me. Except I'm still 18 and I got my 1991 2.3 about 7 months ago.

If I were you, I would try to swap out the engine for the 5.0. Rebuild your 2.3 if you want to spend less money. For the cost I'd say your on the right track, try to look for a donor to just swap out all the upgraded parts you'll need to the 2.3.

As for the body work, do you have some pics? Also good luck with all the work and whatever you end up doing, as I too plan on facing the same route as you some day.

[Slumlord]

Too bad you are in Il. I have an extra 2.3 I am looking to part ways with.

[b_chandler]

I got my '91 from a family member for free with the very same problem. My family has owned this particular car since new. We even bought my wife's '06 new from the same dealership.

The rod bearing that went bad also damaged the crank. So I bought a crank kit (refurbished crank and bearings) 1 new rod because the old one was too far gone to be resized properly, and a set of rings. Since the cylinders were still pristine, I used the original pistons and had the cylinders honed for the new rings. I also had a valve job done on the head while I had it apart.

I did all the work except for the machine work. I did the R&R, the disassembly and the re-assembly of the engine. Including gaskets, and oil, I spent about $750.00.

The motor is still running strong after 4 years. The only problem I've had was a bad (read: Cheap) freeze plug failure at the back of the block that dumped all the coolant and overheated the motor. And that just happened a little over a year and a half ago.

[Smitri]

Thanks for the help/advice all. I suppose I need to almost double some of my estimates if I want to have this done somewhere, correct? Unfortunately, living at a trailer means I do not have access to a good garage to pull the engine and even if that were not the case i'm not so sure I could do it without a good deal of assistance.

While on that subject...anyone have a recommendation for a shop in/around the southern Illinois area?

I will post pics sometime next week. Thanks for any additional help that can be provided. I'm leaving town for a couple days so I may not be quick to respond.