[DBLJ]

Im assuming you see your gas gauge alot now? I mean I wouldnt stop driving my TJ if i had a Hemi.

[tx_jeepguy]

That is awesome!
Right now I just got my front grill put back on, with the radiator. Power steering hoses causing the same problem for me. I went to literally 3 different places in the area and none of them would modify the hoses for me. I have the hose from the '05 ram and that seems to work ok, it does have an excess loop in it but not too bad. I got the interior almost completed too, waiting on the console to come in but everything else is where it needs to be. I will be out for work for a few days so won't have a chance to get on it until next week. I'm going to start the wiring then. Decided to do it myself since I don't have the money to have it made. Should be fun. I'll put some pictures of the motor install when I have a chance.

[fordfreak$]

This post is really motivating me to spend more money then I have and install my warmed over 306!!!!! Have you found out why your having issues above 4000RPM?

Also...Did you really expect those "turbo" baffle things to quiet the beast down???

Wish I could drive it!!! Post up the 1/4 times when it's done!!!!!!!!!!!!!!

[tx_jeepguy]

I am having a hard time getting the wiring right. Does anyone have direct experience with making the wiring harness? I don't have the money to get one made right now.

[cincytj]

Originally Posted by fordfreak$

This post is really motivating me to spend more money then I have and install my warmed over 306!!!!! Have you found out why your having issues above 4000RPM?

Also...Did you really expect those "turbo" baffle things to quiet the beast down???

Wish I could drive it!!! Post up the 1/4 times when it's done!!!!!!!!!!!!!!

the 4000RPM issue was low trans fluid

when I put fluid in originally I did not put in enough. after I replaced the pan and filter I refilled it drove and checked. It took 4 cycles of fill drive and check to get it full. then it went as high as I wanted.

[tx_jeepguy]

Breathing a little more life into this thread (I hope!) I got mine running, but it's still not on the road yet. Little things are killing me, like the trans cooler (blew the lines off yesterday, made a huge mess.) If anyone is interested, this is it running, sans exhaust:
http://www.youtube.com/watch?v=E-eH-_fzgBA

[tx_jeepguy]

OK, I got it back from the muffler shop. I am just not comfortable enough to make it myself, but it runs and sounds awesome now.

Does anyone know a part number for an air filter which can bolt on to the stock ram air intake? The oval shape measures 4x3.5, best as I can tell.

I'll get some videos when the weather clears up here.

[cincytj]

Originally Posted by tx_jeepguy

OK, I got it back from the muffler shop. I am just not comfortable enough to make it myself, but it runs and sounds awesome now.

Does anyone know a part number for an air filter which can bolt on to the stock ram air intake? The oval shape measures 4x3.5, best as I can tell.

I'll get some videos when the weather clears up here.

I used the dodge ram tube, then cut a piece of conduit to adapt it to a cone filter I got at PepBoys, it sets it facing the front all the way over to the left.

[PacificNWJeeper]

This is, by far, the BEST write up I have seen on the net and I have been researching for several months. I am starting my own 5.7 swap in a 97 TJ with a 2005 hemi and 545RFE. I will post once I start digging at the end of 2010. I have compiled a list through my research of what I will need, hope this helps someone. Also, any input on anything would be helpful, especially since I think I have it all covered.


1997 2.5 TJ Swap List


1) $4,000.00 = 2005 - 2007 5.7 Hemi Dodge Ram 1500 complete drivetrain with Computer, Wiring harness and 5 speed 545RFE automatic transmission.
* 2004 and prior Hemi's have known weak bottom end. 2005 and up are the better choice - per "Mopars Collector Guide". However 2006 on up all have the MDS system (shuts down 4 cylinders when not in use). It appears the 2005 will be the best fit and least hassle.
* Ensure engine comes with flat black key not the grey key which means it had S.K.I.M. (security feature) installed. If unsure run VIN by dealer to verify. The security feature was an option, just keep searching.
* I do not want A/C so I do not need to worry about running lines.

· If possible, have wrecking yard run gas stabilizer through motor before pulling out to help clean out injectors.

· Get trans lines and fuel lines.

· Make sure engine has all sensors especially the Temp Sensor and Oil Pressure Sensor.






2) $1,540.00 = Hot Wire Harness set and reprogram computer.
3) $54.99 = Teraflex Transmission mount.
4) $447.99 = Teraflex Belly-Up transmission skid plate for Hemi 5.7.
5) $200.00 = 2005 Grand Cherokee Hemi exhaust manifold (fits perfectly between TJ frame). Advanced adapter part #716601
6) $110.00 = 2001 TJ, or newer, instrument cluster. 97-00 instrument clusters do not work with Hemi engines.
7) $200.00 = 2005 TJ, or newer, complete 19 gallon gas tank (includes fuel pump).
8) $5.00 = Block off plate for hole in firewall left my removing clutch master cylinder.
9) $23.09 = Teraflex transfer case shifter linkage adapter.
10) $255.30 = Advanced Adapters 5.7 Hemi Motor mounts with steering brace platform part #713098
11) $545.00 = All aluminum radiator from Griffin Radiators with 16lb cap Part # 5-787LA-MXX .
12) $177.80 = JeepSpeedShop.com Gas Pedal and Gas Pedal mount. Grand Cherokee 2005 pedal..
13) $45.00 = 2002 Vapor Canister
14) $140.00 = 2001-2002 Natural Vacuum Leak Detection pump, aka Emissions Control Module.

15) $190.00 = Need to replace NP231 spline to 23 spline for Advanced Adapters

16) $140.00 = FlowMaster 70 2.25 inch muffler.

17) $? = Engine compartment stickers from dealer for donor vehicle, part # is on bottom left of sticker.

18) $? = Shifter. I wanted BUM but they do not make one for the 545rfe, I thing the Grand Cherokee Hemi shifter will be the choice, not sure?

19) $80.00 = Hoses for radiator.

20) $572.24 (price for 2)= two Magna Flow 2.25 inch ‘spun’ pre cat converters part # 99655HM

21) $232.93 = Magna Flow Grand Cherokee 2.25 inch converter for 5.7L Hemi. Part # 99236HM



I know I will also need:
- Exhaust including one muffler and a cat. price ?
- 2 O2 Sensors
- 2 radiator hoses
- Battery Cables
- Oil Filter
- Air Filter
- Fluids...
- Engine block will need 3/8’s clearance from fire wall.
- Welding required: To install the new motor mounts & to re-weld the steering shaft brace on top of the platform provided by advanced adapters on the motor mounts.


Questions:
-Mechanical fan. I know there is one that will swap onto the motor but I don' recall which car it comes off of? 4.7 liter Durango fan will work.
-What do I need to adapt the 545RFE transmission to the NP231 transfer case? Is it just a new input shaft? Transfer case to tranny - I had to get a new input shaft coz I was re-using the original transfer case which had a 21 spline due it being from a 2.5L the 4.0L has the 23 spline and does not need to be modified.issue?

-What do you do about fuel lines? Fuel lines - I used the TJ hard line and just got a 5/16 connector for the hard line side, a 3/8 line and then a 3/8 connector to the hemi fuel rail.
-What do you do about trans cooler lines? Tranny cooler lines - just run brake line or power steering line to your cooler, matching up fittings.
-What do you do about power steering lines? Power steering lines - you can keep the original low pressure line but modify the high pressure line.

Other good resources:
- I bought the Extreme 4x4 DVD with the TJ Hemi swap. Good stuff..
- Burnsville.
- AEV
- JeepSpeed
- HotWireAuto
- Teal-J write up (think in four wheelers mag. website)
- This website any everyone that has answered my emails. thanks guys.

[perndawg]

Originally Posted by PacificNWJeeper

This is, by far, the BEST write up I have seen on the net and I have been researching for several months. I am starting my own 5.7 swap in a 97 TJ with a 2005 hemi and 545RFE. I will post once I start digging at the end of 2010. I have compiled a list through my research of what I will need, hope this helps someone. Also, any input on anything would be helpful, especially since I think I have it all covered...

Wow. When reading this post from PacificNWJeeper I had to ask myself if it wasn't actually me who posted this while extremely tired and just didn't remember posting it. It is so nearly exact to me, my research, my purchases etc. 97 TJ vs my 99 TJ, RAM Hemi, 545RFE 4x4 DVD, Teraflex parts, etc. I will have a private site soon, and I'll post links to the before and during pics so far. I'm going to have a file server setup for free access to my own write ups, pics videos, research etc so anyone can download them.

I would add that the AC lines are available from two places, Advanced Adapters is one of them. I forgot the other but I'll find it and post it.

Also, Hotwire (previously Squire) wants everyone to know that they can now put any pigtails on any harness. See, some yards won't sell just the cluster and some only have the cluster. Squire will even work with you over the phone and tell you what to cut, where to cut for lead lengths and then they will ask you exactly what they need to know about your part choices and custom build the perfect harness. My quote was just over 1800 bucks though.

The tip about the security was a hugely important tip! Avoid security keys!

Great job finding, organizing and posting all of this! Thanks to everyone else for their info also!
John Pernia

[ltcoyote]

Originally Posted by PacificNWJeeper

* 2004 and prior Hemi's have known weak bottom end. 2005 and up are the better choice - per "Mopars Collector Guide". However 2006 on up all have the MDS system (shuts down 4 cylinders when not in use). It appears the 2005 will be the best fit and least hassle.

So why is the MDS system not recommended for the swap? This is my next 'upgrade' and I wanted to do the swap on my 2006 LJ with a 2006 5.7 Hemi to keep it all legal. Will the MDS engine still work? BTW, great write up.

[PacificNWJeeper]

Yes you can make the MDS system work (hotwireauto.com) talk to Tony.
If you do not want the MDS system you are stuck with the MDS components inside of the block (which you can take out but is a pain) which is just another piece to go wrong down the road. Good luck....

[ltcoyote]

thanks. I will give them a call.