Novak Conversions Jeep Wrangler TJ engine mounts

Daubies at home HEMI conversion

Hooking up your O/D isn't hard.

You need a momentary connection to a ground. The easiest way is to use a relay with a momentary switch hooked up to it. The switch energizes the coil in the relay and you use that to connect the O/D wire to a ground. I have a push button switch on my center console but you could use the dash switch if you wanted to. I'd have to look at a 05-06 schematic to see how it's connected but it shouldn't be a big deal one way or the other.
 
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Wildman said:
Hooking up your O/D isn't hard.

You need a momentary connection to a ground. The easiest way is to use a relay with a momentary switch hooked up to it. The switch energizes the coil in the relay and you use that to connect the O/D wire to a ground. I have a push button switch on my center console but you could use the dash switch if you wanted to. I'd have to look at a 05-06 schematic to see how it's connected but it shouldn't be a big deal one way or the other.
Click to expand...

Rick - does the stock OD switch drive a relay, or just go straight to ground?
 
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NashvilleTJ said:
Rick - does the stock OD switch drive a relay, or just go straight to ground?
Click to expand...

Wildman said:
I don't know, I've never worked on a TJ that had O/D but I don't think so, I think the PCM did the grounding of the circuit.
Click to expand...

The OD switch latches to ground to turn overdrive off on my 2005. The PCM senses the grounding via that wire and does its thing to turn OD off.

I verified this last year by grounding the dark green (DG) wire. The FSM pin-out page agrees with those findings.


Screen Shot 2024-10-11 at 1.25.21 PM.png
 
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MikeE024 said:
The OD switch latches to ground to turn overdrive off on my 2005. The PCM senses the grounding via that wire and does its thing to turn OD off.

I verified this last year by grounding the dark green (DG) wire. The FSM pin-out page agrees with those findings.


View attachment 564881
Click to expand...

But the question is does the PCM act as a relay or is there something else being used? Again it's not a hard thing to install since the wiring is already there.
When I did the Magnum swap the first time the shop that did the swap forgot to leave the wires for the O/D. So I had to disassemble the PCM plug and add the wire for O/D and then wire it all in. I used a momentary toggle switch that time but I like this push button switch I have now better,
 
I had a toggle switch mounted on the center console for the O/D when I had the Magnum V-8. The other switch was for the electric fan.

IMGP0889.JPG
 
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Just for fun, a short video of startup idle and 3000rpm rev checking muffler sound.
Not sure I'm completely happy with the muffler I have on it now..

 
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Wildman said:
It sounds pretty good to me. What type of burble are you wanting?
Click to expand...

The right one.....

LOL


Maybe something a little lower, not as raspy.
I really like the factory Hellcat and SRT sound, but it might take full duals to achieve that..
I'm in no hurry, it's just something on my wish list.
 
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Reading through the thread now, was going to DM you, but don't have enough to initiate a DM, only a reply. Apologies on reviving an old thread, but I'm in the process of acquiring a 2005 AEV build TJ Unlimited, and the radiator has a leak. AEV used multiple setups until they settled in on a final version (which this is not), and they used multiple vendors, so part numbers aren't readily available.

As stated, I'm going through the thread now, looking for info on your cooling setup. Which radiator? Which fan setup? Upper/lower radiator hose Part #s, etc. The current setup has an electric fan, but in my communications with AEV, they recommended I go with the mechanical fan. I am totally willing to freshen the entire cooling system, I just need direction, part numbers, etc. AND, I plan on doing the body lift/motor mount lift to accommodate 35s, so any feedback on how that impacts the cooling setup, etc. Your cooling setup looks super clean, and (hopefully?) easily repairable?
 
Agar426 said:
a 2005 AEV build TJ Unlimited, and the radiator has a leak.
Click to expand...

I think you need to answer a few simple questions to figure out your solution;

1 - Has the current cooling system worked for that Jeep? If so, why not rebuild/replace the current radiator and roll on?
2 - What significant changes did AEV make, and would the change-to be worth it?
3 - Other than the leak, what issues do you need so solve?

I suggest taking the simplest path over firing off a parts cannon for an unknow reason.
 
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BlueC said:
I think you need to answer a few simple questions to figure out your solution;

1 - Has the current cooling system worked for that Jeep? If so, why not rebuild/replace the current radiator and roll on?
2 - What significant changes did AEV make, and would the change-to be worth it?
3 - Other than the leak, what issues do you need so solve?

I suggest taking the simplest path over firing off a parts cannon for an unknow reason.
Click to expand...

Great points, agreed!

So, this Jeep has had cooling issues since day one. It was an earlier conversion from AEV, so they hadn't settled on their final configuration. For example, their end configuration uses off the shelf hoses, whereas this one has a hybrid hose. Local mechanic has had to work on it several times over the years, replacing the hose several times, trying different fans, etc.. The latest setup included the addition of a Spal fan, which seemed to work "ok," but the temp gauge does still creep up on warm days. I'm happy simply replacing the radiator, but if there is a configuration that is better, more reliable, etc., then I'm willing to go that route.



1 - Has the current cooling system worked for that Jeep? If so, why not rebuild/replace the current radiator and roll on? Not really, it's had issues over the years.
2 - What significant changes did AEV make, and would the change-to be worth it? According to them, they finally ended up with a custom radiator, OEM mechanical fan, OEM TJ shroud, off the shelf hoses. I have reached out to them for part #s.
3 - Other than the leak, what issues do you need so solve? Without the leak, the system maintains temp fine in cold weather, struggles in hot weather.
 
Agar426 said:
Great points, agreed!

So, this Jeep has had cooling issues since day one. It was an earlier conversion from AEV, so they hadn't settled on their final configuration. For example, their end configuration uses off the shelf hoses, whereas this one has a hybrid hose. Local mechanic has had to work on it several times over the years, replacing the hose several times, trying different fans, etc.. The latest setup included the addition of a Spal fan, which seemed to work "ok," but the temp gauge does still creep up on warm days. I'm happy simply replacing the radiator, but if there is a configuration that is better, more reliable, etc., then I'm willing to go that route.



1 - Has the current cooling system worked for that Jeep? If so, why not rebuild/replace the current radiator and roll on? Not really, it's had issues over the years.
2 - What significant changes did AEV make, and would the change-to be worth it? According to them, they finally ended up with a custom radiator, OEM mechanical fan, OEM TJ shroud, off the shelf hoses. I have reached out to them for part #s.
3 - Other than the leak, what issues do you need so solve? Without the leak, the system maintains temp fine in cold weather, struggles in hot weather.
Click to expand...

I found the section where it speaks to the cooling system, great pics, and super clean swap! Genuinely looks OEM!!
 
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Agar426 said:
Reading through the thread now, was going to DM you, but don't have enough to initiate a DM, only a reply. Apologies on reviving an old thread, but I'm in the process of acquiring a 2005 AEV build TJ Unlimited, and the radiator has a leak. AEV used multiple setups until they settled in on a final version (which this is not), and they used multiple vendors, so part numbers aren't readily available.

As stated, I'm going through the thread now, looking for info on your cooling setup. Which radiator? Which fan setup? Upper/lower radiator hose Part #s, etc. The current setup has an electric fan, but in my communications with AEV, they recommended I go with the mechanical fan. I am totally willing to freshen the entire cooling system, I just need direction, part numbers, etc. AND, I plan on doing the body lift/motor mount lift to accommodate 35s, so any feedback on how that impacts the cooling setup, etc. Your cooling setup looks super clean, and (hopefully?) easily repairable?
Click to expand...

Agar426 said:
Great points, agreed!

So, this Jeep has had cooling issues since day one. It was an earlier conversion from AEV, so they hadn't settled on their final configuration. For example, their end configuration uses off the shelf hoses, whereas this one has a hybrid hose. Local mechanic has had to work on it several times over the years, replacing the hose several times, trying different fans, etc.. The latest setup included the addition of a Spal fan, which seemed to work "ok," but the temp gauge does still creep up on warm days. I'm happy simply replacing the radiator, but if there is a configuration that is better, more reliable, etc., then I'm willing to go that route.



1 - Has the current cooling system worked for that Jeep? If so, why not rebuild/replace the current radiator and roll on? Not really, it's had issues over the years.
2 - What significant changes did AEV make, and would the change-to be worth it? According to them, they finally ended up with a custom radiator, OEM mechanical fan, OEM TJ shroud, off the shelf hoses. I have reached out to them for part #s.
3 - Other than the leak, what issues do you need so solve? Without the leak, the system maintains temp fine in cold weather, struggles in hot weather.
Click to expand...

First you might want to read here... https://wranglertjforum.com/threads/gen-iii-hemi-swap-into-tj-reference-guide-swap-info.46347/

Next: I saw your post on Facebook asking for guidance also. I just did my Hemi swap but mine is a 97 TJ....

Your ability to being able to use a mechanical fan is partly going to depend on radiator core thickness and mounting of the radiator.

AEV offered some nice products along the way.

If you're going to do a body lift then you'll have to either stick with an electric fan or modify the fan schrod since I doubt there is any motor mount lift.
There are electric fans available now that can cool the Hemi. Read this thread. https://wranglertjforum.com/threads...pal-19-850-watt-electric-brushless-fan.78963/

I have a Wizard Cooling radiator & SPAL 300 watt fan. NashvilleTJ has a LJ and Hemi & I don't remember what his brand of radiator is but he's running the SPAL 500 watt fan and it's cooling his engine fine. I started having overheating issues in Aug but I think my issue is a thermostat issue. Been laid up so I haven't had a chance to figure mine out yet.
 
I’ll share my current experience and maybe @Wildman and @NashvilleTJ will chime in soon.
My situation is somewhat unusual. I drive my LJ a lot. It’s almost a daily driver for me but I also use it to tow a 3200# travel trailer and then unhook from it and trail ride and sightsee or adventure wherever we go. So it’s a Swiss Army knife type rig.
When I did my Hemi swap I used a stock replacement water pump, thermostat and a custom CG&J radiator with a flex-a-lite black magic electric fan for TJs. I used the same hoses as @Daubie3. I do have Air conditioning and a transmission cooler and power steering cooler in my grill with a warn 9.5 ctis winch in front of everything. My radiator is a down flow style with a built in oil cooler. The CG&J radiator is a really nice and well made piece. BUT immediately I had overheating issues. You’ll read about them in this thread. With the Efan i would overheat at highway speeds. Pretty much anything above 45-50 and it would hit 245-250 degrees within 10 miles. So I reluctantly swapped the Efan for the stock jeep 4.0 fan and shroud with some modifications to the shroud to fit the Hemi inlet and outlet on the radiator. I did not overheat at 55mph but it would overheat at idle and if towing. So I swapped to the explorer fan and severe duty clutch. I hated it. It was very loud and you could just feel it suck the power out of the engine. Now I could tow at 60-65 before overheating but it still overheated at idle, in traffic, and when moving slow offroad. I tried a standard clutch in place of the severe duty with little change in the noise. The I found a similar fan design that was on a Jeep WJ I think. I tried the Dorman replacement for it (620-082) and matching standard duty clutch. It is significantly quieter and less drag on the engine. But still overheated under the same circumstances. Then I tried the severe duty clutch for it (Hayden 2791). And only slightly more noise but still overheated. I found a Flowcooler water pump for the truck Hemi. That’s where I’m currently at.
 
Wildman said:
First you might want to read here... https://wranglertjforum.com/threads/gen-iii-hemi-swap-into-tj-reference-guide-swap-info.46347/

Next: I saw your post on Facebook asking for guidance also. I just did my Hemi swap but mine is a 97 TJ....

Your ability to being able to use a mechanical fan is partly going to depend on radiator core thickness and mounting of the radiator.

AEV offered some nice products along the way.

If you're going to do a body lift then you'll have to either stick with an electric fan or modify the fan schrod since I doubt there is any motor mount lift.
There are electric fans available now that can cool the Hemi. Read this thread. https://wranglertjforum.com/threads...pal-19-850-watt-electric-brushless-fan.78963/

I have a Wizard Cooling radiator & SPAL 300 watt fan. NashvilleTJ has a LJ and Hemi & I don't remember what his brand of radiator is but he's running the SPAL 500 watt fan and it's cooling his engine fine. I started having overheating issues in Aug but I think my issue is a thermostat issue. Been laid up so I haven't had a chance to figure mine out yet.
Click to expand...

Thank you! This is the rabbit hole I'm going down now. I know I want 35s, but the way they did it back when AEV was building them was to use the longer coils, which over the years was determined to cause other issues, hence the now "standard" 4" suspension + 1.25" body, with 1" motor mount lift. I'm not a fan of body lifts, but willing to do it to get the "proper" level of performance (that's a can of worms, I know). But, there don't seem to be any COTS MM lifts for the hemi swap, etc, etc, etc. Can open, worms everywhere......at least from my untrained hands. I own an AEV TJ already, but it has the 4.0, this unlimited is my friend's Jeep, we ordered them from AEV at the same time. I'm basically getting the Jeep I wish I could have bought to begin with.
 
Novak Conversions Jeep Wrangler TJ engine mounts
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