Gen III Hemi Swap into TJ Reference Guide & Swap Info

If I was starting with my Jeep now and doing a engine swap I'd be seriously looking at a Hemi over the Magnum V-8. But with owning a 1997 with a 01/96 build date I'd have to swap out the gauges & wiring from a newer TJ. It isn't a HUGE issue but it does make it a little more of a hassle compared to starting with a newer TJ.

When I started my swap back in 2005 a Hemi engine & trans take out was $10K if not more since they were basically a new engine which is what kept me from doing the Hemi swap back then. And as pc1p has talked about the 408 stroker he has it's a MONSTER for power but as has been noted before the Hemi or LS will get BETTER MPG than the Magnum.
My logic for keeping it 318 Magnum is just less work overhead. Already having purchased a fully converted harness, bellhousing, ecm, and other parts. I just need a good magnum donor and mounts as well as a radiator solution.

For a newer JK, I would definitely consider the Hemi swap. I have the current 5.7 in the Durango and that thing is a beast, plus great mileage when traveling long distances on the road
 
...And as pc1p has talked about the 408 stroker he has it's a MONSTER for power but as has been noted before the Hemi or LS will get BETTER MPG than the Magnum.
Man, knowing that I’m getting maybe 10 on a good tank - you are in trouble Rick.
 
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My logic for keeping it 318 Magnum is just less work overhead. Already having purchased a fully converted harness, bellhousing, ecm, and other parts. I just need a good magnum donor and mounts as well as a radiator solution.

For a newer JK, I would definitely consider the Hemi swap. I have the current 5.7 in the Durango and that thing is a beast, plus great mileage when traveling long distances on the road
FWIW, I got rid a recently bored and prepped 5.9L Magnum block, 75% of the rebuild parts, already-prepped crank and rods, and a ton of new accessories (water pump, timing chain, aftermarket cam, ECM, headers, 2 spare harnesses, etc) for my Hemi. Having just built the 408 Magnum, I knew how much I would spend to get the power levels I wanted out of it. Then I still needed to build the trans (a 46RE) to work with it...

At the end of it, when I ran the numbers, my estimate was that I would spend almost 2x the money on the Magnum rebuild to get to what the Hemi was getting bone stock. I keep detailed spreadsheets so I will see if that math turns out to be true :) Even if the cost still comes out to be equal, I know I'll have a modern platform with lots of potential (if I ever want) plus have the opportunity to learn a new platform.
 
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My logic for keeping it 318 Magnum is just less work overhead. Already having purchased a fully converted harness, bellhousing, ecm, and other parts. I just need a good magnum donor and mounts as well as a radiator solution.

For a newer JK, I would definitely consider the Hemi swap. I have the current 5.7 in the Durango and that thing is a beast, plus great mileage when traveling long distances on the road

Yep I wouldn't change now as I have everything for the Magnum swap. I have a BUILT 46RE that was made to handle 600 HP so that is covered. With my 318 I was getting the same mileage as the guys running the 4.0 on the trail. I never took a long enough road trip to see what kind of on road mileage I was getting.

But I also know this 408 (6.7) is going to be thirsty as heck.


Since you have everything already I would just look for a core block and do a rebuild on it. If you weren't so far away I'd let you have a radiator for cheap. But any TJ radiator for a Chevy swap is the same for the Magnum.

Man, knowing that I’m getting maybe 10 on a good tank - you are in trouble Rick.

I guess we'll have to see. Maybe it was a good thing I stuck with the magnum... It's also why I want a 20 gal tank either fuel cell or GenRight inframe.
 
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At the end of it, when I ran the numbers, my estimate was that I would spend almost 2x the money on the Magnum rebuild to get to what the Hemi was getting bone stock. I keep detailed spreadsheets so I will see if that math turns out to be true :) Even if the cost still comes out to be equal, I know I'll have a modern platform with lots of potential (if I ever want) plus have the opportunity to learn a new platform.
For sure

Yep I wouldn't change now as I have everything for the Magnum swap. I have a BUILT 46RE that was made to handle 600 HP so that is covered. With my 318 I was getting the same mileage as the guys running the 4.0 on the trail. I never took a long enough road trip to see what kind of on road mileage I was getting.

But I also know this 408 (6.7) is going to be thirsty as heck.


Since you have everything already I would just look for a core block and do a rebuild on it. If you weren't so far away I'd let you have a radiator for cheap. But any TJ radiator for a Chevy swap is the same for the Magnum.



I guess we'll have to see. Maybe it was a good thing I stuck with the magnum... It's also why I want a 20 gal tank either fuel cell or GenRight inframe.
Appreciate it brother. For me, in the TJ currently, I will not need more than the Magnum musters. Having 20gal or more tank is a good way to not have to stress too much on fuel.
 
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Gonna test fit the motor tomorrow!

Decided to work on the 2005 gas tank today and get it cleaned out. I figured it would be good to get it prepped and ready, plus even though I have all the openings covered up the best I can, it still stinks a little like gas near the tank and I'll be happy to rid my garage of that smell :)

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Like @Wildman said, buying a full rig is often the best approach. If space allows, this is the best way to ensure you have everything you will need, while also having the opportunity to recoup some $$ in the long run. I did the same when I needed a 5.9L core for my RamCharger. I ended up buying a complete 1999 Ram, pulled the engine, trans, t-case, ECM and some other parts, then sold what was left. I ended up making $$ in the long run.

Now that said, with the popularity of Gen III swaps (Hemi and LS), there are many scrap yards and auto recyclers who will pull everything necessary for you (engine, trans, harness, TPIM, ECM, pedal, etc). You will pay more than you would if you bought a wreck/parts rig, but there is some convenience there.


I hear you there... I'm hardly a 4.0L fan. It's a reliable motor, but a tractor motor nonetheless. It took me about 5 months of constant searching to find all the parts I needed and I'm still getting some (some parts I needed other parts to confirm what I need first, exhaust manifolds for example).

For a guy in the planning stages of a swap, do you think it would be better to buy a whole truck, or just piece together what you need? Wheeling in the sand and mud, I need some horsepower... The 4.slow isn't the right engine. I can't get to it for at least a year, but I might start accumulating parts...


Both platforms are excellent. For me, the Hemi just makes the most sense since it's the most compatible with what is already in the Jeep (or at least what was available from the factory in certain years). The fact that I can keep it 100% emissions compliant with nothing more than a few locally sourced parts was the biggest advantage. With the Gen III Hemi swaps becoming increasingly popular, the aftermarket support is skyrocketing as well, which only makes it more appealing. Throw in the fact that a set of factory 2009+ Eagle heads will flow over 330 CFM is absolutely bonkers if I ever want to make this thing scream :)
I've had an LS...I don't care for the power delivery of the more recent GM engines. Feels like your gotta rev them to redline to get any power. I was leaning that way just because of cost and aftermarket support.

Frankly, I don't know what I'd do with 345/375 out of an early gen 3. That seems like an insane amount of power for a wrangler.

I think it's time to start buying engine tools. The 403 olds in my motorhome is gonna need a rebuild, and this hemi thing might be a fun project!
 
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I've had an LS...I don't care for the power delivery of the more recent GM engines. Feels like your gotta rev them to redline to get any power. I was leaning that way just because of cost and aftermarket support.
You know the first time I drove an LS-based truck (5.3L/4L60E) I wasn't particularly impressed either. To be fair though,it was the same as with a 2007 Ram 1500 5.7L. From what I can gather, it's a combination of DBW (drive by wire) programming, transmission shift programming, torque converter stall speed, and generally the mild cam profile that favored efficiency at higher RPMs. I think the engineering and tuning teams at almost all the major MFGs struggled with how to take advantage of the new head flow and how to replicate the "feel" of electronic pedals.


Frankly, I don't know what I'd do with 345/375 out of an early gen 3. That seems like an insane amount of power for a wrangler.
I always chuckle when people say something like "what, are you building a race Jeep?" when someone suggests a V8 swap. A V8 swapped SWB Jeep like a YJ or TJ is an experience. I haven't been in a Hemi swapped TJ/YJ (I have been in a Hemi JKU and that was sweet), but I have been in a handful of V8 swapped ones (a mild SBC, an early 4.8L LS one, and a Magnum one - plus a few built AMC V8 CJ's) and will say that once you do, it's hard to go back to even a 4.0L rig.


I think it's time to start buying engine tools. The 403 olds in my motorhome is gonna need a rebuild, and this hemi thing might be a fun project!
If I were doing something like a motorhome, I would certainly be looking at a 6.0LS or 6.4 BTE (big truck engine) Hemi with any of the modern 8-speed transmissions (the 8HP90 is damn near perfect IMO).
 
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Transmission Update

In case you missed it in the earlier post about it, the 545RFE and 65RFE are considered "modular" transmissions. While most transmissions can be converted from 2x4 to 4x4 configuration, many needed to be disassembled in order to do so and many needed new/modified output shafts. The 545/65RFE is different; going from 2WD to 4WD is simply a matter of bolting on the correct tailshaft housing/extension.

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[Factory 2x4/RWD tailshaft of the 2012 65RFE I'm using for my swap]

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[Removal of 2WD tailshaft extension]

Removal requires nothing more than removing the 15mm socket bolts around the perimeter of the adapter, then using a small rubber mallet and a putty knife to break free.

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[4x4 t-case adapter installed]

Both the 2WD and 4WD extensions are installed with Black RTV. My transmission-rebuilder friend (the one who gave me the extension for free) suggested "Ultra Grey" since the black will sometimes weep. When a trans rebuilder for 20-years suggests something, you do it! :)

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[Output shaft stickout w/t-case adapter installed]

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[Output shaft stickout; edge of shaft to t-case mounting surface]

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[New overall length of 65RFE w/4WD t-case adapter installed - nearly exactly 27"]
 
If I were doing something like a motorhome, I would certainly be looking at a 6.0LS or 6.4 BTE (big truck engine) Hemi with any of the modern 8-speed transmissions (the 8HP90 is damn near perfect IMO).
My first LS was an 02 Avalanche. Underwhelming to say the least. You're right though. A tune really does wake them up. My colorado is tuned with the HF 3.6L engine. It made a huge different, but its still lacks for torque. the 8 speed transmission puts my RPM so low that it lugs all over (I'm sure this sounds familiar to the 42RLE guys). It really needs some gears, and I think it would be a pretty good powerplant.

The motor home is kind of a unique duck. Its a '78 GMC transmode (think Stripes). FWD and use the Hydramatic 425 3 speed.. The Engine is lengthwise in the chassis, and the transmission runs parallel and beside it. It has three reverse gears, and one forward gear, if you were to put it where it should live normally. Same drivetrain as a late 70's Toronado or Caddy Eldo. Packaging constraints dictate that I stay with that platform.
 
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My first LS was an 02 Avalanche. Underwhelming to say the least. You're right though. A tune really does wake them up. My colorado is tuned with the HF 3.6L engine. It made a huge different, but its still lacks for torque. the 8 speed transmission puts my RPM so low that it lugs all over (I'm sure this sounds familiar to the 42RLE guys). It really needs some gears, and I think it would be a pretty good powerplant.

The motor home is kind of a unique duck. Its a '78 GMC transmode (think Stripes). FWD and use the Hydramatic 425 3 speed.. The Engine is lengthwise in the chassis, and the transmission runs parallel and beside it. It has three reverse gears, and one forward gear, if you were to put it where it should live normally. Same drivetrain as a late 70's Toronado or Caddy Eldo. Packaging constraints dictate that I stay with that platform.
I was curious so I Googled what the Transmode was, since I have very little experience with motorhomes (my mother had one for a short while and my friend has an older Winnie that I've helped with but that was all Dodge stuff). That sounds like an interesting setup from a packaging standpoint, but certainly limits options. I'd love to restore an old one - maybe once I get my shop :)
 
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I was curious so I Googled what the Transmode was, since I have very little experience with motorhomes (my mother had one for a short while and my friend has an older Winnie that I've helped with but that was all Dodge stuff). That sounds like an interesting setup from a packaging standpoint, but certainly limits options. I'd love to restore an old one - maybe once I get my shop :)

They are a PITA to work on...
 
They are a PITA to work on...
GMC motorhomes or just motorhomes in general? Curious if you've worked on the GMC's before, cuz I'll pick your brain if you have!
I was curious so I Googled what the Transmode was, since I have very little experience with motorhomes (my mother had one for a short while and my friend has an older Winnie that I've helped with but that was all Dodge stuff). That sounds like an interesting setup from a packaging standpoint, but certainly limits options. I'd love to restore an old one - maybe once I get my shop :)
Yeah, ours was finished out by Coachman. Its a 1978 and its in pretty good shape. Less than 100,000 Original miles. I went through the top end and cooling system last winter. This year, I'm working on the generator, and my wife wants to re-do the headliner...which is the worst of the interior. I have to rebuild the suspension (front and rear) for peace of mind, but it doesn't keep us from using it. I have a thread in the off-topic section here, if you'd like to read a bit more about it.

Ok, enough disruption from the Good Stuff in this thread!
 
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GMC motorhomes or just motorhomes in general? Curious if you've worked on the GMC's before, cuz I'll pick your brain if you have!

I was a heavy line mechanic for 3 years at a Ford/RV dealership.
I worked on 2 of those GMC motorhomes while there.
 
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Got the motor set in the mounts...

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It's tight, so I definitely want to get the trans bolted up today or tomorrow to see how it fits. As you can see below, there is a good bit of space in front of the firewall to reach down from above to get to the bellhousing bolts.

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You can see that the firewall is clearly meant for a narrow motor, so it's deep in the center but the sides (in front of the driver/passenger footboards) do get close to the valve covers).

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The A/C compressor outlets are close to the frame - hopefully I can make something work there!

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This motor came with a 45º oil filter adapter. I think it has to go as it is already close to the upper control arm mount on the front axle. I wonder if a standard straight-down filter would work. If not, I'll look at a remote filter kit...

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You can clearly see above why the Ram manifolds won't work for a Jeep swap...
 
That intake configuration is going to look great under there. Mine...not so much. I’m running the older ram setup with the throttle body on top, and the A/C compressor front and center. Ugly.
 
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Man that LOOKS great. Really looking good. And just like with the Magnum only some exhaust manifolds will work where the others dump right where those do.
 
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Man that LOOKS great. Really looking good. And just like with the Magnum only some exhaust manifolds will work where the others dump right where those do.
dcc-77072462_xl.jpg


I ordered these - it's a set of the factory newer 6.4L SRT Jeep manifolds that are also sold under Mopar Performance Kit #77072462 - these are supposedly damn near perfect and will match my Eagle-headed D-shaped exhaust ports. These handle 707hp in factory form, so I suspect they'll be just fine for my 400hp NA motor.

That intake configuration is going to look great under there. Mine...not so much. I’m running the older ram setup with the throttle body on top, and the A/C compressor front and center. Ugly.
I hope to make it as stock looking as possible - I'll see if I can manage something. I put a hole in my cowl for the Aerostar filters - was wondering if I could take advantage of that and run a cowl intake. It's getting really crammed underhood :)
 
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View attachment 228670

I ordered these - it's a set of the factory newer 6.4L SRT Jeep manifolds that are also sold under Mopar Performance Kit #77072462 - these are supposedly damn near perfect and will match my Eagle-headed D-shaped exhaust ports. These handle 707hp in factory form, so I suspect they'll be just fine for my 400hp NA motor.

I'd like to try some headers like this instead of the block huggers that I have but no one that I can find has ever tried to use any of these. My thought is that if it works on a Ram truck or Jeep Grand Cherokee they "SHOULD" work in the TJ but as you know it doesn't work that way.

https://www.amazon.com/dp/B001CI62MY/?tag=wranglerorg-20
 
View attachment 228670

I ordered these - it's a set of the factory newer 6.4L SRT Jeep manifolds that are also sold under Mopar Performance Kit #77072462 - these are supposedly damn near perfect and will match my Eagle-headed D-shaped exhaust ports. These handle 707hp in factory form, so I suspect they'll be just fine for my 400hp NA motor.


I hope to make it as stock looking as possible - I'll see if I can manage something. I put a hole in my cowl for the Aerostar filters - was wondering if I could take advantage of that and run a cowl intake. It's getting really crammed underhood :)
I run a cowl intake on mine as well. That stroked Hemi puts out a crazy amount of heat, and it was roasting my IAT’s.
 
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