Advice on 92 1500 engine repair/swap

Jared Stangenberg · January 10, 2016

So to make a long story short, the crankshaft in my truck is toast (92 1500 2wd w/5.7), if you'd like the longer version of the story you can read it here.

After having to leave my truck sitting dead in the driveway for the last couple months, it looks like I will have some money to do something about it after I get my taxes done. It won't be a ton of money, maybe $2000, but that's more than I've had to work with.

For this price range I'm thinking I can do one of the following:

1) Remove the current engine block and have it inspected and machined if necessary, then obviously replace the crankshaft and whatever else may come up through the process. It seems this might be the cheapest option and leave some money for addressing other issues the truck has.

2) Getting something along these lines, I don't feel like I can afford much of a crate/complete motor for less than $2k.

3) I've seen people say that you can pull off a Vortec (Gen III 5.3 in particular) swap for less than $2000, but I'm skeptical.

I know the option could also be out there to buy a parts truck or otherwise used engine. My wife would be pretty hesitant to agree to dropping the money on any type of used motor at this point (I'm a little wary of it too).

I'm also slightly ignorant of what swaps might be "straight forward" and what swaps would require more extensive work.

Also, to be perfectly honest, I'm in over my head and will be relying on the help of friends who are more experienced with these types of things. I will have access to an engine hoist and stand and if needed we can tow the truck to a shop with an overhead lift to work on it.

It'll be a bit before we actually get to work on it, I'm just trying to educate myself as much as possible in the meantime. Thanks in advance for any advice.

Blazerblitz · January 11, 2016

Hey,

I've done the swap. Be skeptical Unless you can do most/all of the work yourself, it's going to cost you no less than $4k (more like $6-$8k).

Rebuilding (someone else doing it) will probably cost you $3K. Doing most of the work yourself and letting a machine shop do what they do will cost you about $800. If you can do the R&R, you'll save about $2.5k, but if you cannot, then add that in.

Remind me if your truck has legit EFI, or if it's TBI still. If it's TBI, your stock fuel tank and sending unit will handle a Gen III fuel system because you have the baffles in the tank, but you will need to swap the in-line fuel pump with one from a mid 90's pickup. I can give you a specific model if you need it. If you have EFI - you'll still need to up your pump, but you probably will not need to mess with a regulator.

There are people who have done the swaps for under $900. They are lucky, and the posts are probably older, too - like back before everyone started doing it. Most boneyards now charge about $450 for an engine, and you really don't know anything about it. 6 years ago you could get an engine for like $250, but that is pretty rare now. You can buy an engine online (complete dropout) or find something local, and they range $900 to $4K depending on the milage and such. If you go this rout, be sure to get a complete dropout engine (cpm/tcm, fuse box, al accessories). Gen III is drive-by-cable, so you can retain your stock gas pedal, but if you went Gen IV like I did, you'll need the donor's gas pedal and wire too.

Jared Stangenberg · January 11, 2016

My truck is a TBI.

That said, I really am leaning toward the rebuild. I think I can do a good deal of it by myself or with a friend who will help for free. In addition to probably being the cheapest option, I can have more control over the parts going back into the truck this way.

I've found a couple of online sellers who sell already rebuilt blocks and heads, but anytime I start to look into reviews for those sellers things go downhill fast.

Blazerblitz · January 12, 2016

Rebuild or crate are probably the most feasible options for you - especially if you and a buddy can eat the labor. When I did the swap, redesigning the fuel system was surprisingly the biggest pain in the a$*. I seriously did not foresee how much of a problem it could be. I wanted to retain the stock steel lines instead of braided hose, but all the adapters to everything out there are AN, so you have to get creative with hooking up to Saginaw fittings. The fuse box that I got was a cheap piece of crap and it caused fuel pump relay issues that were not easily detectable so I dropped my tank to play with the pump 3 times (at the recommendations of professional mechanics, too).

Needless to say, swaps are fun, but any one little thing like the relay can set you back in time and money. If you're not impetuous by nature, or your ride isn't a toy, I would stay clear of a swap. The people that say they did it all just fine and dandy for under $1K are extremely lucky or full of crap and probably don't realize how bad their system actually is.

Have you checked out Summit or Jegs motors. You can get a brand new engine for under $2K

http://www.jegs.com/p/Chevrolet-Performance/GM-Goodwrench-350ci-Engine-Packages/752506/10002/-1

http://www.jegs.com/p/Chevrolet-Performance/GM-Goodwrench-1987-95-Truck-350ci-210HP-Engine/753961/10002/-1

I would imagine TN is loaded with local builders too. Could probably get a nice rebuilt engine for $1.5 - $2.5.

Good luck!