My HEMI build thread - chronicles of a NOOB. - Page 20

**Shobes** · 06-22-2012, 11:06 AM

Man, I will cry the first time you bang a body panel on the rocks

...it's like a work of art!

**AlexGeorgakis** · 06-25-2012, 07:19 PM

It's 4am here and I just got back from the garage so I'll keep this update short.

I can't remember if I have mentioned it already (I'm posting from my iPhone) but the 2005 Dodge Ram 3500 truck ECU does not communicate with the 2000 TJ gauge cluster due to communication protocol differences so I bought a 2003 cluster and ordered the relevant upgrade plugs from Hotwireauto.com. I received the new plugs today and got the cluster to work as well. The only problem I'm having is to get the alternator to work. I bought a high output alternator from Mean Green for a Grand Cherokee but I have a feeling the Ram computer doesn't want to become friends with it. I emailed Mean Green so hopefully they will respond by tomorrow.

If you decide to go down this route and get an after market wiring harness you'll need two things: a) to know the exact year of your Jeep. Better yet insist that the supplier looks it up using your VIN. b) ask them to supply you with all off-engine sensors along with the corresponding plugs. This way you won't have to research part numbers.

**AlexGeorgakis** · 06-29-2012, 08:15 PM

Most of the Jeep is done but we still have some problems to sort out.

1) the TH400 transmission isn't giving any power to the Atlas. We checked fluid levels but nothing. Any ideas???

2) Got some issues with the lights. We'll solve those later.

3) One RCV axle shaft is too long by around 3/4"!!! We'll open the differential to see if it's something from the ARB system which is causing this. Also the covers are interfering with the knuckle bolt heads!!!

4) Other problems as well but minor stuff...

**AlexGeorgakis** · 07-03-2012, 03:55 AM

Quote:

Originally Posted by AlexGeorgakis

Most of the Jeep is done but we still have some problems to sort out.

1) the TH400 transmission isn't giving any power to the Atlas. We checked fluid levels but nothing. Any ideas???

2) Got some issues with the lights. We'll solve those later.

3) One RCV axle shaft is too long by around 3/4"!!! We'll open the differential to see if it's something from the ARB system which is causing this. Also the covers are interfering with the knuckle bolt heads!!!

4) Other problems as well but minor stuff...

After talking to a transmission specialist that knows TH400s inside out, he advised that the reason the transmission isn't giving any power is because it's not pumping any ATF, and there are two possible causes for this:

a) either the oil pump is stuck or blocked
b) the oil pump isn't turning.

The most probable senario is the second, because the oil pump turns only when the torque converter is fully engaged on the transmission (must touch the rear plate). If the torque converter is pulled out slightly its teeth will not engage onto the spline of the transmission shaft which will not turn the oil pump.

Remember, I installed an adapter plate to match the transmission to the HEMI and so I have created a gap between the torque converter and the rear plate of the transmission.

We're now going to add a spacer between the flex plate and the torque converter so that it can engage properly and see if that solves the problem.

**Shobes** · 07-18-2012, 06:00 AM

How's everything going Alex? It's been A few weeks!

How's the power train working, what kinks are you still working out?

**AlexGeorgakis** · 07-18-2012, 06:53 AM

Yeah I haven't had much time to work on the Jeep with the wedding and now the honeymoon. The mechanic has made some progress though.

The spacer idea worked out after all. I can't understand why the adapter plate manufacturers don't include it in their kits. There's no way a TH400 will work without a spacer.

We had two remaining problems. The first was that the alternator wasn't giving any power. That problem was solved by an alternator specialist. There was some issue with the polarity. I'll find out more when I get back.

The second problem is that the HEMI's steering pump is pushing double the flow and pressure of the stock 4L pump. This creates a lot of heat and noise which blew out the piping. I found a pressure regulator from Heidts and will order it next week. With that out of the way the Jeep will be 100%...or so I think!

And here's a picture of the honeymoon!!!

**mrblaine** · 07-18-2012, 08:24 AM

Quote:

Originally Posted by AlexGeorgakis

The second problem is that the HEMI's steering pump is pushing double the flow and pressure of the stock 4L pump. This creates a lot of heat and noise which blew out the piping. I found a pressure regulator from Heidts and will order it next week. With that out of the way the Jeep will be 100%...or so I think!

It's very unlikely that the pump is putting out almost 6 gallons a minute at 3000 psi. You could run a wood splitter with that.

Before putting a pressure regulator on something that already has one built into it, I would make sure that the return and pressure lines are plumbed correctly.

**AlexGeorgakis** · 07-18-2012, 08:56 AM

We checked the routing and initially we had installed it in reverse. We corrected the routing but the problem didn't go away so we took the pump to be flow tested.

Apparently some WKs have hydraulic radiator fans which are powered from the steering pump. These WKs are equipped with much stronger pumps which seems to be what I have. I can't remember the flow value off the top of my head but the guy said it was double the flow of the 4L pump and the pressure was anywhere between 95-110psi. I "think" the TJ's steering gear needs 80psi max or something.

As a test we used a small vice to clamp down on the hose and see how the system responded. Noise was reduced and the steering gear started working again. Only problem is that I don't know if this is healthy for the pump.

**mrblaine** · 07-18-2012, 09:03 AM

Quote:

Originally Posted by AlexGeorgakis

We checked the routing and initially we had installed it in reverse. We corrected the routing but the problem didn't go away so we took the pump to be flow tested.

Apparently some WKs have hydraulic radiator fans which are powered from the steering pump. These WKs are equipped with much stronger pumps which seems to be what I have. I can't remember the flow value off the top of my head but the guy said it was double the flow of the 4L pump and the pressure was anywhere between 95-110psi. I "think" the TJ's steering gear needs 80psi max or something.

As a test we used a small vice to clamp down on the hose and see how the system responded. Noise was reduced and the steering gear started working again. Only problem is that I don't know if this is healthy for the pump.

The max system pressure of the TJ pump is about 1400 psi. Another reason it took the aftermarket a long time to get pumps dialed in. Most pumps are 11-1200 psi and 2gpm. The TJ pump is almost 3gpm.

If the WK pump is one that used to run a hydraulic fan, get one from a model that didn't have the fan. I'm pretty sure you don't want to run the pump against a pressure regulator all the time.

**AlexGeorgakis** · 07-18-2012, 09:14 AM

Are you sure about the 1400psi value??? Then again it's Blaine writing so yes you are sure! :-)

I kinda liked the high pressure and high flow because the next conversion would be hydraulic assist. I would have preferred not to waste another $400-$500 on a new pump but it looks like that's what I'm going to have to do in the end. The regulator only costs $85.

I'll see if I can find a used one, unless you can source one for me...?

**Shobes** · 07-20-2012, 05:50 PM

Man that looks like a pretty good way to spend a few days!

Glad to hear that things are coming together for the most part, sorry but I have no advice for you on the steering pump!

**AlexGeorgakis** · 07-21-2012, 12:57 AM

Oh, the other thing I forgot to mention is the shifter. Since the gear selector on the TH400 is way up front compared to the 32RH, the stock shifter doesn't work. We tried making a shift mechanism similar to what Lokar does but the lever doesn't shift easily. Also, the TH400 and the Atlas t-case don't have backup switches so I ended up ordering B&M's Megashifter both for its cable operation and for its integrated backup switch.

**AlexGeorgakis** · 08-01-2012, 12:44 AM

You asked for 'em so here they are. First day on road today at 8:00am on the way to get new exhaust pipes built. There's still A LOT of work to be done. The body needs to be lowered, the lights to be installed, rear fenders, steering system, and much more. So this is just a preview.

I know what many of you are going to ask...YES, IT HAS CRAZY POWER!!!!!!! I was scared to push on the gas pedal!

**AlexGeorgakis** · 08-01-2012, 07:34 AM

By the way, I'm still having steering pump pressure problems. I had to disconnect it completely. The steering wheel obviously was heavy as hell and since I haven't installed a steering stabilizer, the steering wheel almost broke my fingers when I tried to drive onto a curb.

We're going to try to retrofit a steering pump out of a 3.7L Grand Cherokee. Hopefully it will work. I'll keep this pump for my future hydraulic assist.

**Shobes** · 08-01-2012, 04:12 PM

Quote:

Originally Posted by AlexGeorgakis

You asked for 'em so here they are. First day on road today at 8:00am on the way to get new exhaust pipes built. There's still A LOT of work to be done. The body needs to be lowered, the lights to be installed, rear fenders, steering system, and much more. So this is just a preview.

I know what many of you are going to ask...YES, IT HAS CRAZY POWER!!!!!!! I was scared to push on the gas pedal!

Man that thing is awesome, It's past form looked great but now it just looks perfect! Nice work!
I have nothing of huge value to add on the power steering but are you looking at anything from psc? Easy to spend somebody else's money

http://www.pscmotorsports.com/95-02-...ssist-kit.html