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Unread 10-16-2011, 09:27 PM   #1
sduncan
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And so it begins...5.7 Hemi conversion

I finally have secured enough( I hope) $$ to get my Hemi swap started and completed by the end of the year. I'll be working with and getting tech help and all the needed parts from Todd at Jeep Speed Shop. This is something that I have wanted to do for the past few years and am looking forward to getting it done and back on the road soon. I'll be taking pix and documenting quite a bit of the conversion and posting some of the highlights here.

So here it goes..

Today I pulled the entire harness so it can be shipped out to be mated up with the Hemi harness. I also dismantled most of the accessory wiring and removed the ARB compressor, the Premier Welder, the EVAP, the cruise control and all the other items attached to the fenderwells. The radiator,condensor,grill, winch and bumper were removed too.

Tomorrow I plan to get the fenders off and get the rest of the drivetrain ready to pull on Tuesday.

jeep-swap2.jpg  
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 10-16-2011, 09:56 PM   #2
RubiconRazorbac
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Subbed.

I've been hoping someone would post a JSS-supported swap!
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Quote:
Originally Posted by Imped View Post
Your shaft isn't long enough to handle that kind of droop...
My build thread: http://www.jeepforum.com/forum/f9/ru...thread-792423/
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Unread 10-16-2011, 10:02 PM   #3
ejg
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Unread 10-16-2011, 11:42 PM   #4
Sgt.Fuzz
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Consider me subbed.
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[COLOR="Blue"]My build: [url]http://www.jeepforum.com/forum/f22/fuzzbucket-build-1126577/[/url][/COLOR]
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Unread 10-17-2011, 03:47 AM   #5
chmo
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After JSS ignoring my mails I went the LS1 way ... I got the impression they are still moving from one location to the other
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"The more I know, the more I realize how much I don't know"
my LS1 swap build thread
THE cheap progressive bump stop solution
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Unread 10-17-2011, 07:50 AM   #6
Lawrence
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Quote:
Originally Posted by chmo View Post
After JSS ignoring my mails I went the LS1 way ... I got the impression they are still moving from one location to the other
Same experience here. I emailed Todd about buying some stuff from him, got a response, sent a clarification of what I needed, and never heard back.

OP - Good luck with the swap. Once you're done you'll wonder why you didn't do it sooner.
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Unread 10-17-2011, 09:28 PM   #7
joe108
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watching and
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Unread 10-17-2011, 09:55 PM   #8
sduncan
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Well I accomplished a little today....hood, and fenders off. I had to take a couple of hours to go pick up my cherry picker and weld some new swiveling casters on it....It helps a lot when the damn thing rolls smooth.

I'm planning on pulling the motor tomorrow and getting the harness shipped off.

More to follow...
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 10-18-2011, 08:21 PM   #9
sduncan
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Motor and trans are out..and for sale!! I'm ready to pick up the hemi and parts and get started. So far it has been just basic disassembly. Nothing difficult at all..More to follow soon...
motor-out1.jpg   motor2.jpg  
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 11-16-2011, 06:56 PM   #10
sduncan
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A quick update:

I picked up my 5.7 and trans a few days ago along with most of the parts needed for the swap but I'm still waiting for a few things to be drop shipped to me. What I'm needing the most at the moment is the motor mounts.
The frame is ready for the mounts and then some paint. I've already finished the Savvy body lift and the fuel pump swap and I located an 05 dash cluster and the plugs and wiring for it so that will be done shortly.
Today was spent chasing misc parts and getting the motor ready to go in

Its coming along pretty well so far. Here's a pic of the motor..
motor.jpg  
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 11-16-2011, 08:21 PM   #11
J03_TJ
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How are you getting by with smog. Only reason is I live in Reno and am being told that our DMV requires that the motor has to have been offered in the model you are putting it in. Sucks if it's true that Nevada's smog laws are more stringent than Ca's.
I'm envious if you can't tell. Good luck with the conversion.
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Unread 11-18-2011, 03:26 PM   #12
sduncan
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In Cali it has to be the same "type" of vehicle, (light truck or SUV for the TJ) same year or newer and all original emissions equipment from the new motor has to be installed. It goes to the BAR referree for certification and if all is right, its legal. JSS has done numerous Ca legal conversions and that is one of the reasons I chose them. Being legal was a priority for me in this project.
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 11-22-2011, 09:19 PM   #13
sduncan
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We got a lot accomplished today.

The motor mounts arrived and I am finally feeling well enough to go outside (felt like crap the last few days).
I have to say this...the Advanced Adapters motor mounts are THE way to go to mount a Hemi in a TJ. They use a "gauge" and index off a hole in the frame. Set the gauge, clamp them down, double check your measurements and burn them in. The block mounts fit perfectly as well. I welded them out, painted the frame and mounts and we slid the motor in like it was meant to be there. I've done factory replacements that didn't go as smooth. The rear setup used the JSS mount bolted to the factory mount and attached to the Rubicon Express skid. I had to drill jus two holes( as previously told I would)
to make it all work. It was all just too easy..
Before the motor went in I did a little touch up paint on it. As it sits right now the motor is in. Tomorrow I crack the transfer case for seal replacement and to check the chain and wear parts. If all looks good I'll get it in and hooked up.
A few pics for now.
motor-mount-2.jpg   motor-mount-3.jpg   motor-6.jpg   motor-1.jpg  
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 12-03-2011, 10:33 PM   #14
sduncan
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Pre fab of the exhaust done today. I am using JK cats mounted in the factory (for an 06 Ram truck) location. We still need to add the bungs for the (4) 02 sensors and TIG weld it up. We used 2 in. and 2 1/2 in tubing with a Magnaflow muffler. Once thats done it can go in permanently and I can finish up the underside. I am supposed to get the harness and the radiator next week (I hope) and get the fenders etc back on. I'll post more pics when I get it installed...
exhaust.jpg   exhaust-2.jpg  
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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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Unread 12-17-2011, 10:32 PM   #15
sduncan
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I have figured out something...getting the old motor out and getting the new one in is the easiest part of the whole deal. Its all the little stuff that takes forever..
Fuel line...goes from the jeep 5/16 to Hemi 3/8 quick connect.
Power steering...converting the lines to fit the jeep steering box to the Hemi PS pump so I had a custom pressure line built. The return is 1/2 hose in off the resevior but 3/8 to the steering box. I'm running a PS cooler and making the line. See the pics.
Exhaust...making it all fit and Cali legal...A medium sized PITA...Thanks to my buddy Edwin at Avenger Mfg.
I'm placing an order Monday for a new NP 231HD transfer case from JB Conversions. It'll have the wide chain, 6 pinion planetary, short input gear, and a Super Short SYE with a 1350 series flange for the driveline. I really don't want any issues when out and about.
I got my Novak Cable shifter for the transfer case delivered. (Thanks Gerald.)

So I did get a few things done today..Trans cooler lines, 02 sensors in, PS cooler is ready to go, PS lines in, fuel line done, Fenders and grill back on...
I need the radiator, the harness(2 wks out..Thanks Chris Squire @ Hotwire for pushing it thru and lots of good tech help)) the NVLD system, and to get the drivelines done after the t-case gets here.
A few pics below..








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'98 TJ, 5.7 HEMI, 545RFE, G2 33 spl. D44, HP D30,ARBs,4.10s, RE 4.5 LA,Savvy 1.25 BL,35in MTRs w/Pro Comp 15x10 alloys, Warn 9.5 cti w/Amsteel rope, Gen Rite G3 Alumium front fenders and rear flares, Premier Power welder 195 amp,Savvy Rockers,Prothane bumps,LED tail lites, Rampage top
Link to my Hemi build thread http://www.jeepforum.com/forum/f9/so...rsion-1277803/
YouTube video..http://www.youtube.com/watch?v=iaDRq...&feature=g-upl
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