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Old 12-31-2009, 07:16 PM   #1 (permalink)
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1997 Tj 2.5 L

I am getting prepared to make a 5.7 Hemi swap into my 97 TJ 2.5l. I have researched just about everything from the Harness, to brackets, gas pedal, computer, blah, blah, blag... AEV, Hot Wire, JeepSpeed, and Brownsville seem to have all the 'stuff/parts' covered. One question to throw out there, is there a better year/model/make that the 5.7 Hemi came in over other year/make/models? Right now it appears the 2004 Dodge trucks 4x4 with the Hemi's are the right choice. I have not seen many blogs/comments on donor vehicles from 2005 on including Cherokee's, Commamders, etc. Which is the best year/make/model to search for that will make this not too painful conversion possible? You can see what I started out with, my fully stock 1997 TJ getting it's first "MOD", 4 130 watt ProComp lights - no frills....
Thank you ahead of time for any input.
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Old 01-03-2010, 05:22 PM   #2 (permalink)
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I found that pre 2005 Hemi's had a 'known' weak bottom end that, after time, could not handle the power. I found this in 'Mopar's Collectors Guide'. The bottom end was 'beefed' in 2005 on up and is better suited for handling the power. In speaking with some Hemi builders I found the real change came to in 2006 and it is was recommended to me to find a 2006 or newer motor. So I am looking for 06-08 5.7 Hemi...
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Old 01-05-2010, 08:20 PM   #3 (permalink)
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Alright, here is some of the homework I have done in order to line up the list of thing I will ned for my 5.7 Hemi 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".
* 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.
* I do not want A/C so I do not need to worry about running lines.
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).
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) $306.99 = Teraflex 5.7 Hemi motor mounts.
11) $700.00 = Aluminum Radiator for 5.7 hemi.
12) $177.80 = JeepSpeedShop.com Gas Pedal and Gas Pedal mount.
13) $45.00 = 2002 Vapor Canister
14) $140.00 = 2001-2002 Natural Vacuum Leak Detection pump, aka Emissions Control Module.



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...


Questions:
-Mechanical fan. I know there is one that will swap onto the motor but I don' recall which car it comes off of?
-What do I need to adapt the 545RFE transmission to the NP231 transfer case? Is it just a new input shaft issue?
-What do you do about fuel lines?
-What do you do about trans cooler lines?
-What do you do about power steering lines?
-What am I missing?

Any help would be appreciated. i will reciprocate with pictures of the collection process and build as I go.
Thank you
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Old 01-05-2010, 08:21 PM   #4 (permalink)
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Also, I should mention, many of the items I am looking at purchasing are used, such as the 5.7 and the 545RFE (which I will pull from the same vehicle).
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Old 10-05-2010, 11:18 AM   #5 (permalink)
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Bump. So... what's new??
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Old 10-05-2010, 07:46 PM   #6 (permalink)
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Got the 05 gas tank, 97 Tj auto shifter, 03 Instrument cluster, Cover plate for the clutch slave, Gen right rear 4 link kit, Rock jock 60 with 35 spline chromoly shafts - 4.88's- ARB - and Explorer disc brakes. Had to purchase a few tools, Miller 180 with autoset and a compressor. Coming in the mail right now is the 2005 TJ NVLD system (Natural Vacuum Leak Detection). My being patient I have scored great deals:

05 gas tank with all lines and pump = $80.00 Craigslist
97 TJ auto shifter = $45.00 shipped on Ebay
Instrument cluster = $25.00 shipped on Ebay
Cover plate = $2.00 local wrecking yard.
NVLD system = $55.00 shipped Ebay.
Rock Jock & Genright 4 link combined total shipped $5,600.00 from Currie and Genright (Thank you Tony!).

I am looking for a 05-08 Grand Cherokee or Ram Hemi Gas pedal.
Jeep Liberty shifter cable.
2005-2008 5.7 Hemi
2005-2008 5-45RFE trans
Atlas 2 transfer case.
Griffen Radiator for swap.


It is time and money. I am searching hard to score good deals. There was no way around the Rock Jock and 4 link. I know I will bite the bullet on The radiator and Atlas 2 as well. I am being fruggle on the motor and trans.

That's where I'm at as of right now. Shoot me.
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Old 10-05-2010, 07:48 PM   #7 (permalink)
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Old 10-05-2010, 07:58 PM   #8 (permalink)
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Thanks for the updates. I've been tossing around the ideas of ditching my 27k mile drive train and going for the swap.
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Old 10-05-2010, 08:10 PM   #9 (permalink)
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Thanks for the updates. I've been tossing around the ideas of ditching my 27k mile drive train and going for the swap.

Left foot, right foot, left foot.......

Stay on track buddy. V8 Swap is there for whenever you want it
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Old 10-05-2010, 08:26 PM   #10 (permalink)
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Research comes before commitment. Gotta crawl before you can dance. With all the other options changing on my jeep now might be the right time to swap power plants
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Old 10-05-2010, 08:28 PM   #11 (permalink)
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Research comes before commitment. Gotta crawl before you can dance. With all the other options changing on my jeep now might be the right time to swap power plants

I have a line on 6.0's and 4l80E's when the time comes


Sorry for the hijack!!!


I like the idea of a Hemi swap. Is a 45RFE a strong trans? Sorry.... I don't know anything about Dodge stuff. I just drive one, it's new enough I don't work on it
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Old 10-05-2010, 08:57 PM   #12 (permalink)
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Research comes before commitment. Gotta crawl before you can dance. With all the other options changing on my jeep now might be the right time to swap power plants
Research and take your time is key. My initial goal was to make it smog legal and give it a very clean factory look. It's coming, but it will still be a while as I piece it together. I knew I had to ditch the dana 35 before the swap. After the swap is done I will drop my last few dollars into a rock jock up front as well. Overall goal is to keep the Jeep looking like a Jeep with a nice power plant beefed up by parts that wont break.
I figure by next summer (2011) I should have all the parts together and be ready roll on the strip down during the winter of 2011-2012. Till then I am saving every penny I can and looking for smoking deals. 'Dookey' Take the lead and start your swap $'s permitting, let me know if you need help I have an updated list with a boat load more info.. Till then I will keep driving my 188,000 mile drivetrain. Peace Out.....
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Old 10-07-2010, 05:55 PM   #13 (permalink)
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The 2005 NVLD system made it in today. My 97 has no shelf at the passenger rear tire for this. Time to fab up some brackets.
1 - EVAP CANISTER
2 - NVLD FILTER
3 - NVLD PUMP
4 - VAPOR LINES
5 - FLOW VALVE
6 - TOP OF FUEL TANK)
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Old 10-08-2010, 07:11 PM   #14 (permalink)
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Old 10-08-2010, 08:42 PM   #15 (permalink)
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I guess I feel fairly lucky since I have an 06. I already have most of the required Evap stuff.
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Old 10-08-2010, 08:48 PM   #16 (permalink)
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Dookey - Here's an update to my parts list... With your 2006 you will not need to change the tank or NVLD system or the instrument cluster.


1997 2.5 TJ Swap List


1) $4,000.00 = 2005 - 2007 5.7 Hemi Dodge Ram 1500 complete drive train with Computer, Wiring harness and 5 speed 545RFE automatic transmission. (Meridian Auto Wrecking 253/847-1922 & Walt and Verns 888/829-1263)
* 2004 and prior Hemi's have known weak bottom end. 2005 and up are the better choice - per "Mopars Collector Guide".
* 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.
* 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 = Rewire TJ harness and reprogram computer. Hotwireauto.com. Talk to Tony.
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. PURCHASED 02 Cluster. Ebay $40.00
7) $200.00 = 2005 TJ, or newer, complete 19 gallon gas tank (includes fuel pump). PURCHASED 2005 gas tank. Craigslist $80.00
8) $5.00 = Block off plate for hole in firewall left my removing clutch master cylinder. PURCHASED. Ebay $2.00
9) $23.09 = Teraflex transfer case shifter linkage adapter.
10) $306.99 = Teraflex 5.7 Hemi motor mounts.
11) $545.00 = All aluminum radiator from Griffin Radiators with 16lb cap Part # 5-787LA-MXX .
* Need transmission cooler too. $?
12) $177.80 = JeepSpeedShop.com Gas Pedal and Gas Pedal mount. Grand Cherokee 2005 pedal (part # 52109683AB)..or use a dodge ram pedal (part # 53032794AB)
13) $45.00 = 2005 Vapor Canister
14) $140.00 = 2005-2006 Natural Vacuum Leak Detection pump, aka Emissions Control Module. PURCHASED 2005 NVLD. Ebay $50.00
15) If I keep NP231: Need to replace NP231 21 spline to 23 spline from Advanced Adapters $190.00.
If I go with the Atlas it will be a 2 speed 3.8 $2,747.00, per Mathew.
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) TJ automatic Shifter assembly. PURCHASED 1997 TJ shifter with cable. EBay $45.00.
19) Need trans/cable connector off of a Dodge or Jeep 45RFE or the connector off of a Jeep Liberty. This connector fits the TJ cable and mounts on the 5-45RFE.
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
22) $10.22 = 2004 Jeep Wrangler break switch part # 4671336.(Why? Just saw it in a forum)
23) $300.00 Mechanical fan from a 4.7 Liter Durango will work. I am going with a Flexalite electric fan.
24) Fuel Lines: Using TJ hard lines. Will need a 5/16 connector for the hard line side, a 3/8 line and then 1 3/8 connector to the Hemi fuel rail.
25) Trans cooler lines: I will run brake or power steering lines to the cooler with matching fittings.
26) Power Steering lines (JeepSpeedShop may sell them?) If not I will keep the low pressure line and modify the high pressure line myself.
know I will also need:
- 2 O2 Sensors
- 2 radiator hoses
- Battery Cables
- Oil Filter
- Air Filter
- Fluids...
- Engine block will need 3/8’s clearance from fire wall.
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Old 10-08-2010, 08:51 PM   #17 (permalink)
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2) $1,540.00 = Rewire TJ harness and reprogram computer. Hotwireauto.com. Talk to Tony.
I really don't want to talk to Tony. I was researching that price the other day and it is absolutely absurd.
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Old 10-09-2010, 09:33 AM   #18 (permalink)
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I really don't want to talk to Tony. I was researching that price the other day and it is absolutely absurd.
Well, I suck at electrical. Do you have a better contact?
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Old 10-10-2010, 06:18 AM   #19 (permalink)
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Jim's Performance in MD-

he is awesome and costs like 300-500 to get it all done.

doing my harness for my 4.3 swap
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Old 10-10-2010, 07:30 AM   #20 (permalink)
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Jim's Performance in MD-

he is awesome and costs like 300-500 to get it all done.

doing my harness for my 4.3 swap
Now we're talking.
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Old 10-10-2010, 10:32 AM   #21 (permalink)
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Jim's Performance in MD-

he is awesome and costs like 300-500 to get it all done.

doing my harness for my 4.3 swap


Got a phone number for him?
Also, does he reprogram the computer as well?
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Old 01-16-2011, 06:41 PM   #22 (permalink)
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Update? Been watching this build. Just starting the part gathering process to do very much the same....

Great info! Keep it up
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Old 01-16-2011, 07:30 PM   #23 (permalink)
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right on bro,,,,Ive been wondering whats up with the beast. Come on get that junk disassembled and built already.....

Im just gonna rub it in your nose but Im gonna be wheeling the fawk out of mine this spring.

Really you've done your research its gonna be the shit.
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Old 01-16-2011, 07:41 PM   #24 (permalink)
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right on bro,,,,Ive been wondering whats up with the beast. Come on get that junk disassembled and built already.....

Im just gonna rub it in your nose but Im gonna be wheeling the fawk out of mine this spring.

Really you've done your research its gonna be the shit.
Call it Mangina, but I have all the peripheral stuff, still looking for the 5.7 and 454rfe locally, at a good price. It's all about the Benjamin's right now.....
You need to start another build so I can feel like a real loser when you complete two and I am still in the middle of my first...
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Old 01-16-2011, 10:44 PM   #25 (permalink)
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Call it Mangina, but I have all the peripheral stuff, still looking for the 5.7 and 454rfe locally, at a good price. It's all about the Benjamin's right now.....
You need to start another build so I can feel like a real loser when you complete two and I am still in the middle of my first...
Dude I found a web site full of salvaged motors at one time. What about a low mileage 5.3 vortec. I bought a vortec for 500, the computer for 500 and the wiring harness for 500. I guess you've got your mind set on a hemi.

No new projects,,,,Ive been going freaky this winter. I need to build a buggy or some shit.

I did just buy a car hauler and it will need some modification. Im gonna tube out the fenders so I can drive over them. and widen the bed, then a nice coat of paint.
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