Lycoming 540 Overhaul Cost

 

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Should you do this alone?

Does it make any sense to try this on your own? With overhaul, mistakes can cost thousands of dollars and sometimes lives. It doesn’t have to be like that anymore.

We see $30M+ overhauls per year and fixed the old world problems of calling around and rolling the dice. Simply put, we’ll help you save time and decide with confidence.

These tasks don’t have to be difficult:

  • Shop Selection
  • Getting Quotes
  • Analyzing Quotes
  • Learning About Overhaul
Recent Projects

Cessna Turbo Stationair T206, C-T206

San Luis Obispo, California

Lycoming TIO-540-AJ1A Overhaul

Factory Quote

  • $71,743 for factory overhaul
  • Service Limit Engine
  • 7 Week Turnaround

Reputable Overhaul Shop 1

  • $60,295 with New Lycoming Cylinders
  • Add $1,600 for Prop Governor Overhaul
  • Crank/case Repair Included
  • Turbo Included
  • 7 Week Turnaround

Reputable Overhaul Shop 2

  • $68,269 with New Lycoming Cylinders
  • Round Trip Shipping Included
  • Turbo Included
  • Crank/case Repair Included
  • 7 Week Turnaround

Reputable Overhaul Shop 3

  • $36,795 with Overhauled Cylinders
  • Add $5,045 for New Lycoming Cylinders
  • Crank/case Repair Included
  • Turbocharger Included
  • 7 Week Turnaround

Reputable Overhaul Shop 4

  • $58,900 with New Cylinders
  • Crank/case Repair Included
  • Turbocharger Included
  • 7 Week Turnaround

Reputable Overhaul Shop 5

  • $47,000 for Echange & Overhauled Cylinders
  • Add $9,100 with New Cylinders
  • Crank/case Repair Not Included
  • Turbocharger Included
  • 2 Week Turnaround

Piper Cherokee, PA-28-235

Rockwall, Texas

Lycoming O-540-B4B5 Overhaul

Factory Quote

  • $30,236 for Factory Overhaul
  • Service Limit Engine
  • 5 Week Turnaround

Reputable Overhaul Shop 1

  • $28,900 with New Lycoming Cylinders
  • Crank/case Repair Included
  • 7 Week Turnaround

Reputable Overhaul Shop 2

  • $26,397 for Exchange & Overhauled Cylinders
  • Add $2,400 for New Lycoming Cylinders
  • Crank/case Repair Included
  • Round Trip Shipping Included
  • 5 Week Turnaround

Reputable Overhaul Shop 3

  • $23,485 with Overhauled Cylinders
  • Add $2,060 for New Lycoming Cylinders
  • Crank/case Repair Included
  • 7 Week Turnaround

Reputable Overhaul Shop 4

  • $25,900 with New Lycoming Cylinders
  • Crankshaft Repair Included
  • Crankcase Repair Not Included
  • New starter
  • Add $800 for new camshaft
  • 4 Week Turnaround

Cessna 182 RG, C-182-RG

Midland, Texas

Lycoming O-540-J3C5D Overhaul

Factory Quote

  • $32,641 for Factory Overhaul
  • Service Limit Engine
  • 7 Week Turnaround

Reputable Overhaul Shop 1

  • $25,900 with New Lycoming Cylinders
  • Crank/case Repair Included
  • 5 Week Turnaround

Reputable Overhaul Shop 2

  • $23,500 with Overhauled Cylinders
  • Crank/case Repair Included
  • One Way Shipping Included
  • 4 Week Turnaround

Reputable Overhaul Shop 3

  • $27,725 for Exchange & Overhauled Cylinders
  • Add $2,400 for New Lycoming Cylinders
  • Crank/case Repair Included
  • Round Trip Shipping Included
  • 5 Week Turnaround

Reputable Overhaul Shop 4

  • $23,500 with New Lycoming Cylinders
  • Crankcase Repair not Included
  • Crankshaft Repair Included
  • Add $900 for new Camshaft
  • 4 Week Turnaround

Reputable Overhaul Shop 5

  • $23756 with Overhauled Cylinders
  • Crank/case Repair Not Included
  • 6 Week Turnaround

Reputable Overhaul Shop 6

  • $30,000 with New Lycoming Cylinders
  • Crank/case Repair Included
  • 8 Week Turnaround

Reputable Overhaul Shop 7

  • $25,700 For Exchange & Overhauled Cylinders
  • Add $3,300 for New Lycoming Cylinders
  • Crank/case Repair Not Included
  • 3 Week Turnaround

Piper Saratoga, PA-32R-301

Trenton, New Jersey

Lycoming IO-540-S1A5 Overhaul

Factory Quote

  • $44,090 for Factory Overhaul
  • Service Limit Engine
  • 7 Week Turnaround

Reputable Overhaul Shop 1

  • $34,700 with Overhauled Cylinders
  • Removal and Reinstallation Included
  • Crank/case Repair Not Included
  • 9 Week Turnaround

Reputable Overhaul Shop 2

  • $42,370 for Exchange & Overhauled Cylinders
  • Add $42,370 for New Lycoming Cylinders
  • Crank/case Repair Included
  • Round Trip Shipping Included
  • 5 Week Turnaround

Reputable Overhaul Shop 3

  • $36,900 with New Lycoming Cylinders
  • Crankcase Repair not Included
  • Crankshaft Repair Included
  • Add $800 for new Camshaft
  • 4 Week Turnaround

Reputable Overhaul Shop 4

  • $31,345 with Overhauled Cylinders
  • Add $9,535 for New Lycoming Cylinders
  • Crank/case Repair Included
  • 8 Week Turnaround

Reputable Overhaul Shop 5

  • $38,900 with New Lycoming Cylinders
  • Crank/case Repair Included
  • 6 Week Turnaround

Reputable Overhaul Shop 6

  • $29,600 with Overhauled Cylinders
  • Add $7,200 for New Lycoming Cylinders
  • Crank/case Repair Not Included
  • 4 Week Turnaround

Lycoming 540 Overhaul Cost (factory supported models)

Engine ModelAverage
Factory New		Average
Factory Rebuilt		Average
Factory Overhauled		Independent
Shop
Overhaul		TBO
IO-540-AA1A5723154832444324Get Bids12yrs or 1,600hrs*
IO-540-AA1B5664984322239222Get Bids12yrs or 1,600hrs*
IO-540-AB1A5667994348639486Get Bids12yrs or 2,000hrs*
IO-540-AC1A5749855066546665Get Bids12yrs or 2,000hrs*
IO-540-AE1A5723574836044360Get Bids12yrs or 1,400hrs*
IO-540-C1B5626873988035880Get Bids12yrs or 1,800hrs*
IO-540-C4B5629354017036170Get Bids12yrs or 1,800hrs*
IO-540-C4D5632224034836348Get Bids12yrs or 1,800hrs*
IO-540-C4D5D644394130137301Get Bids12yrs or 1,800hrs*
IO-540-D4A5620853935135351Get Bids12yrs or 2,000hrs*
IO-540-D4B5635454063236632Get Bids12yrs or 2,000hrs*
IO-540-G1D5698584616842168Get Bids12yrs or 1,600hrs*
IO-540-J4A5661474291438914Get Bids12yrs or 2,000hrs*
IO-540-K1A5465323074442064Get Bids12yrs or 2,000hrs*
IO-540-K1A5D721844820944209Get Bids12yrs or 2,000hrs*
IO-540-K1B5702224648842488Get Bids12yrs or 2,000hrs*
IO-540-K1E5705614678542785Get Bids12yrs or 2,000hrs*
IO-540-K1F5706424685742857Get Bids12yrs or 2,000hrs*
IO-540-K1G5678664442140421Get Bids12yrs or 2,000hrs*
IO-540-K1G5D706934690242902Get Bids12yrs or 2,000hrs*
IO-540-K1H5698084612542125Get Bids12yrs or 2,000hrs*
IO-540-K1J5695734591941919Get Bids12yrs or 2,000hrs*
IO-540-K1J5D703684661642616Get Bids12yrs or 2,000hrs*
IO-540-K1K5682934479740797Get Bids12yrs or 2,000hrs*
IO-540-L1C5708024699642996Get Bids12yrs or 2,000hrs*
IO-540-M1A5704104665342653Get Bids12yrs or 2,000hrs*
IO-540-M1C5726294789443894Get Bids12yrs or 2,000hrs*
IO-540-N1A5676854426340263Get Bids12yrs or 2,000hrs*
IO-540-R1A5688654604442044Get Bids12yrs or 1,800hrs*
IO-540-S1A5720494809044090Get Bids12yrs or 1,800hrs*
IO-540-T4A5D686664512441124Get Bids12yrs or 2,000hrs*
IO-540-T4B5635634064836648Get Bids12yrs or 2,000hrs*
IO-540-T4B5D655084235438354Get Bids12yrs or 2,000hrs*
IO-540-V4A5646424159437594Get Bids12yrs or 2,000hrs*
IO-540-W1A5307521942134890Get Bids12yrs or 2,000hrs*
IO-540-W1A5D649884189737897Get Bids12yrs or 2,000hrs*
LTIO-540-F2BD922276233556835Get Bids12yrs or 1,800hrs*
LTIO-540-J2B898616030754807Get Bids12yrs or 1,800hrs*
LTIO-540-J2BD904596076855268Get Bids12yrs or 1,800hrs*
LTIO-540-U2A849265702551525Get Bids12yrs or 1,800hrs*
O-540-A1A5532973384529845Get Bids12yrs or 2,000hrs*
O-540-A1B5534823400830008Get Bids12yrs or 2,000hrs*
O-540-A1C5535593407530075Get Bids12yrs or 2,000hrs*
O-540-A1D5535693408430084Get Bids12yrs or 2,000hrs*
O-540-B1A5550193407230072Get Bids12yrs or 2,000hrs*
O-540-B2B5558803482730827Get Bids12yrs or 2,000hrs*
O-540-B2C5587023730233302Get Bids12yrs or 2,000hrs*
O-540-B4B5556063458730587Get Bids12yrs or 2,000hrs*
O-540-E4A5553173431130311Get Bids12yrs or 2,000hrs*
O-540-E4B5551823423530235Get Bids12yrs or 2,000hrs*
O-540-E4C5550483409730097Get Bids12yrs or 2,000hrs*
O-540-F1B5568603586031860Get Bids12yrs or 2,000hrs*
O-540-G1A5576933641732417Get Bids12yrs or 2,000hrs*
O-540-J1A5D560593498430984Get Bids12yrs or 2,000hrs*
O-540-J3A5548953396329963Get Bids12yrs or 2,000hrs*
O-540-J3A5D572783605432054Get Bids12yrs or 2,000hrs*
O-540-J3C5D624133664132641Get Bids12yrs or 2,000hrs*
O-540-L3C5D646883888134881Get Bids12yrs or 2,000hrs*
TIO-540-A2B902726062155121Get Bids12yrs or 2,000hrs*
TIO-540-A2C945836092255422Get Bids12yrs or 2,000hrs*
TIO-540-AA1AD1169668492779427Get Bids12yrs or 2,000hrs*
TIO-540-AB1AD900076038854888Get Bids12yrs or 2,000hrs*
TIO-540-AB1BD855725649850998Get Bids12yrs or 2,000hrs*
TIO-540-AE2A1197758649580995Get Bids12yrs or 2,000hrs*
TIO-540-AF1B919706210956609Get Bids12yrs or 2,000hrs*
TIO-540-AG1A880375823152731Get Bids12yrs or 2,000hrs*
TIO-540-AH1A1029177204866548Get Bids12yrs or 2,000hrs*
TIO-540-AJ1A1092797728971789Get Bids12yrs or 2,000hrs*
TIO-540-AK1A890235950654006Get Bids12yrs or 2,000hrs*
TIO-540-C1A955876528159781Get Bids12yrs or 2,000hrs*
TIO-540-F2BD913376155456054Get Bids12yrs or 1,800hrs*
TIO-540-J2B891125959754097Get Bids12yrs or 1,800hrs*
TIO-540-J2BD910576071555215Get Bids12yrs or 1,800hrs*
TIO-540-S1AD920096261957119Get Bids12yrs or 1,800hrs*
TIO-540-U2A916955605550555Get Bids12yrs or 1,800hrs*
TIO-540-W2A1140537636170861Get Bids12yrs or 2,000hrs*
540 Avg.715434690043008

*See bottom of page

Lycoming 540 Overhaul Cost by Aircraft

Aircraft ModelAverage
Factory New		Average
Factory Rebuilt		Average
Factory Overhauled		Independent
Shop
Overhaul
A.M.F. 17-D674264265638156Get Bids
AERO FAB LA-2501038537207066570Get Bids
AERO MERCANTIL1197407862572625Get Bids
AEROSTAR 600746524884244342Get Bids
AEROSTAR600731764757843078Get Bids
APEX HR-100658314129036790Get Bids
BELLANCA 300A740744834843847Get Bids
BRITTEN NORMAN BN-2A736574799143491Get Bids
BRITTEN NORMAN BN-2A & BN-2B578153536830868Get Bids
BRITTEN NORMAN BN-2A ISLANDER738394814743647Get Bids
BRITTEN NORMANBN-2577343529830799Get Bids
CESSNA 182667074204037540Get Bids
CESSNA 182RG655193811133611Get Bids
CESSNA 182-S & 182-T696274454040040Get Bids
CESSNA 182-T703364514740647Get Bids
CESSNA T-182934596143855438Get Bids
CESSNA T-2061147287957773577Get Bids
CESSNA TR-182679084041835918Get Bids
CESSNA182-T704104521140711Get Bids
CESSNAC-206787195232447824Get Bids
COMMANDER 114B669074221237712Get Bids
COMMANDER 114TC924236009454093Get Bids
COMMANDER 500 B,S or U Series765384995345453Get Bids
COMMANDER114687684380539305Get Bids
EMBRAER EMB-201738724817443674Get Bids
GIPPSLAND AIRVAN1053227333767337Get Bids
GLASAIR GA81087487445768457Get Bids
KING ENGINEERING759524923344733Get Bids
MACHEN/AEROSTAR SUPERSTAR930535863052630Get Bids
MAULE413222564434578Get Bids
MAULE M-5-235588473625131751Get Bids
MAULE M-6-235682224333738837Get Bids
MAULE M-7-260693014426239761Get Bids
MAULE MX-7-235587913620331703Get Bids
MOONEY M-20M965546401758017Get Bids
MORAVAN Z143L558473368329183Get Bids
NEIVA730294745342953Get Bids
PA-32-301706784544040940Get Bids
PIPER714814612841628Get Bids
PIPER 601-A756364968545185Get Bids
PIPER 602-P759164992445424Get Bids
PIPER 700P954195706151061Get Bids
PIPER MALIBU MIRAGE1257498901283012Get Bids
PIPER PA-23-235577553531630816Get Bids
PIPER PA-23-235/PA-24-250561423525130750Get Bids
PIPER PA-23-250669794238437884Get Bids
PIPER PA-23-250 AZTEC651764073136230Get Bids
PIPER PA-23-250T1003516726861268Get Bids
PIPER PA-24-250585523670632206Get Bids
PIPER PA-24-260683644365139150Get Bids
PIPER PA-25-235615633857634077Get Bids
PIPER PA-25-260605633772033220Get Bids
PIPER PA-28-235584233590831408Get Bids
PIPER PA-28-236601283750633006Get Bids
PIPER PA-31-300739164821143712Get Bids
PIPER PA-31-325958896316957169Get Bids
PIPER PA-31-350935536144255442Get Bids
PIPER PA-32-260579583552131021Get Bids
PIPER PA-32-300744484877244272Get Bids
PIPER PA-32-301716444626641766Get Bids
PIPER PA-32-301T1088107451168511Get Bids
PIPER PA-32RT-300 / 32R-301743124855144051Get Bids
PIPER PA-32RT-300/32R-301 LANCE741144838143882Get Bids
PIPER PA-32RT-300T969876487858878Get Bids
PIPER PA-36-300710124572741227Get Bids
PIPER T-35716934630941809Get Bids
PIPER600-A730434746442965Get Bids
PIPER700P893215891252912Get Bids
PIPER-PA-31-310980036273156731Get Bids
PIPER-PA-31-325968246453158531Get Bids
PIPERPA-31-350955956258856588Get Bids
PIPER-PA-31-350940926192555925Get Bids
PIPER-PA-32-301711704586141361Get Bids
PIPERPA-32RT-300T/PA-32R-301T962026420158201Get Bids
ROBINSON R-44596873718932689Get Bids
ROBINSONR44 II759605062346123Get Bids
ROCKWELL 114720854664442144Get Bids
SIAI MARCHETTI S-208 & SF-260580683556131061Get Bids
SOCATA TB-20676774287138371Get Bids
SOCATA TB-20 TRINIDAD676254269238193Get Bids
SOCATA TB-21944226219256192Get Bids
SOCATA TB-21-TC945626231256312Get Bids
STODDARD HAMILTON698084469540195Get Bids
STODDARD HAMILTON GLASAIR III732834767043170Get Bids

Disclaimer – prices are for reference only. For the same engine model, you may find many different configurations of magnetos, electrical, accessories, ect. which affects price. Hence the reason for ‘average’ costs above.

To get solid pricing on factory engines and overhaul shop quotes, post a project here

*TBO might be different if certain conditions are met. Click here to see what your actual TBO is.

Prices were updated with Lycoming’s latest price increase on January 4th 2016. Overhauled increased 2.5%, Rebuilt increased 3.3%, and New increased 4.9%