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Discussion Starter #1
In a few months I'm getting hold of a 5.9 magnum lump. It's done almost 200,000 but it runs fine and I'm not paying for it. I'm planning on putting it on my bench and stripping it right down and completely overhauling it and either keeping it as a spare or swapping it out for my 5.2.

So this being the place for knowledgeable people I want advice and opinions.

This will be a complete bare bones strip down, so what do you guys recommend I:

Replace?
Refurbish (head skim, cylinder scrub etc)?
Upgrade?

Though making it a performance engine is a nice idea I don't want to spend a fortune on expensive performance parts, so it will more be a refurbishment and only minor upgrades for a reasonably priced performance boost.

Anyone have any experience with increasing the bore on these engines?

What issues should I look out for? What areas or items are prone to heavy wear on these Engines?

Any info or advice you have will be appreciated. If you use acronyms, can you please explain them as I'm originally from England and have found we often use different names for parts.
 

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spend the money to get a good intake manifold. the stock ones are notorious for blowing plenum gaskets..i actually have that on my agenda to fix on mine this weekend. another thing to look at as far as cheap performance....in my opinion...are mopar wires, good plugs, accell ig coil, and cai. if you want to get fancy, i wouldn't trade my superchips flashpaq for anything. another cheap upgrade is 180* thermostat. it's a little annoying not having the best heat in the winter, but it's worth it the way it runs...actually depending on what program you load onto the ecu off of the superchips, they require that you upgrade to the 180 thermo. it's only like 15 bucks. I am running synthetic oil in mine but idk what would be best as far as the fact that you are rebuilding it so it will have "low miles" on it. that's just my input.
 

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the best ppl that i found 2 go through 4 good performance parts is hughesengines.com. these ppl no there mopar. they will help u find the parts u r lookin 4. and if u wanted 2 run synthetic oil from the start u can, ur jus goin 2 hav a longer break in period on the motor, than if u run non synthetic oil.
 

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Send the block , crank , rods/pistons and heads out to a reputable machine shop . Block will probably need to be bored out . The shop can also recondition the rods and press over the new pistons . Crankshaft will new to be polished atleast . The cylinder heads will probably need guides and a good vavle job . Depending on what you want to do performance wise will depend on how much you want to dump into the heads , balancing , and any additional performance enhancing mods . You may want to let the machine shop assemble the bottom end if your not sure how to check the clearances . You could expect to spend $1000 - $1500 to have a decent rebuild .
 
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What he ^^^^ said. Rebuild it but you don't have to go crazy with super exotic parts or nothing to make a bit more power. New main bearings, a higher lift duration cam, you don't need to bore it out so much as to check the cylinders for wear and a little clean up, open up the heads (port/polish), replace the injectors, new oil pump, etc...

Just go with good parts and a good shop.
 

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Great advice guys, thanks all. When I do it, I'll sling together a photo diary of the who job start to finish, not so much to show people a 'how-to', but just to share the experience.
 

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$1500 to have the bottom end and pistons etc rebuilt and worked.....just nosing around I can get a crated completely reconditioned ready to run 5.9 V8 magnum for $2500......makes you wonder if from a money point of view rebuilding it myself is worth it.

Though in all honesty it's not that I need to do this rebuild, will mostly be doing it for the sheer nerdy pleasure of doing it, and I'm in no rush, if it takes me two years to rebuild it with a few hundred spent every 6 months, it won't bother me.

Interesting points though folks, thanks for all the info.
 
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