1991 SUBARU JUSTY

Typical onset: 80,000-140,000 mi

Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Overheating under load, Milky oil on dipstick or cap

Fix: Both head gaskets on this 3-cylinder require removing the intake plenum and exhaust manifold. Resurface head if warped. Budget 6-8 hours labor plus gaskets, timing belts (do them while you're in there), coolant, and oil. Machine shop adds $80-150 if resurfacing needed.

Estimated cost: $800-1,400

Typical onset: 100,000-150,000 mi

Symptoms: Slipping under acceleration, especially uphill, Whining or grinding noise from transmission, Transmission overheating warning light (if functional), Abrupt loss of forward motion

Fix: The electronic CVT in these is rare and parts availability is dismal. Rebuilds are specialty-only; most shops won't touch them. Used transmissions from junkyards are a gamble. Swap is 8-12 hours. Many owners convert to manual if they can source the pedal assembly and linkage.

Estimated cost: $1,800-3,200

Typical onset: 90,000-130,000 mi

Symptoms: Oil puddles under engine after sitting overnight, Oil film on bellhousing or clutch cover, Rapid oil consumption without visible top-end leaks

Fix: Front main seal requires timing belt removal (3-4 hours). Rear main seal means pulling the engine or transmission (6-8 hours). If both are leaking, do them together. Often find oil pan gasket weeping at the same time—add 1 hour.

Estimated cost: $600-1,100

Symptoms: Hard starting when cold, improves when warm, Rough idle that smooths out under throttle, Black smoke and poor fuel economy, Stalling at stoplights after highway driving

Fix: The Hitachi 2-barrel carb develops vacuum leaks, clogged jets, and worn throttle shafts over 30+ years. Rebuild kits are available but hard to find quality ones. Full rebuild is 3-4 hours; cleaning and minor adjustment is 1 hour. Throttle shaft bushings require machining if worn badly.

Estimated cost: $300-650

Symptoms: Transmission fluid dripping near front bumper area, Low transmission fluid warnings or slipping, Visible rust perforation on metal cooler lines

Fix: Steel cooler lines corrode from road salt and age. Replacement lines are NLA from Subaru; fabricate custom lines or use universal transmission cooler kit. 2-3 hours labor including cutting, flaring, and routing new lines safely.

Estimated cost: $250-500

Symptoms: Visible rust perforation in rear wheel wells and rocker panels, Spongy feeling in floor pan under carpet, Front subframe mounting points crumbling, Suspension components pulling through rotten metal

Fix: Salt-belt Justys rust catastrophically. Rear strut towers, rockers, and floor pans go first. Subframe mounts fail inspection. Welding repairs are 10-20 hours depending on scope but often exceed vehicle value. Structural rust is economically terminal for most of these.

Estimated cost: $1,500-4,000

Symptoms: Intermittent gauge cluster failures, Headlights dimming or flickering at idle, No-start conditions that resolve after jiggling battery cables, Random warning lights with no stored codes

Fix: Corrosion at chassis ground points and brittle 30-year-old insulation cause intermittent faults. Clean and re-terminate all major grounds (1-2 hours). Chasing wiring faults can spiral into 4-6 hours if harness damage is extensive. Preventive maintenance: dielectric grease on all connectors annually.

Estimated cost: $150-600