I built my engine to 2005 Ram 5.7 Hemi specifications. Front timing cover/intake/throttle body/alternator/AC/oil pan/etc are all Ram truck pieces…
Any ‘03-‘08 5.7 Hemi block and heads would have worked for a base starting point…
I switched my valve covers & ignition coils to the later 2007+ Hemi ignition setup though. That way there are no plug wires. It’s just a cleaner platform. My ignition coils are basically the same pieces used all the way through units installed on the Hellcats. You just need to let whom ever is building the engine harness know…
I went with a 2005 545RFE 5-speed transmission out of a Durango. Ram would have been the exact same…
Fuel tank and NVLD from any ‘05-‘06 TJ work. They plug in as stock to each other. The only thing I had to change was the fuel line connection. The new electrical plug-in for the fuel pump will already be installed in the new conversion harness…
I mounted the NVLD in the rear passenger side wheel well just like the newer TJs. It only took a bit of trimming and a couple holes drilled…
Any ‘01-‘06 gauge cluster will work. You just need to know what year it is from to get the correct wiring diagram so you can splice the 2 new gauge connectors into your current dash harness…
All you need to do is send your underhood PDC fuse box and it’s attached harness to Chris at HWA and he will work his magic…
Good info, but Just a couple of clarifications. The coil on plug setup did not start in ‘07. My ‘06 runs the coil on plug - but I’m not sure what year they started. It is a nicer setup - especially if you hate spark plug wires (and LS’s…).
The ‘03 to ‘08 Gen III Hemi will work, but for the stock gauges in the ‘01 to ‘06 TJ to work you need to run an ‘05 (or prior) ECU. The ‘06 to ‘08 Hemi (at least in the Ram) used a CAN BUS setup, which is not compatible with the TJ cluster. For the ‘01 and prior TJ, you will need to source an ‘02 to ‘06 TJ gauge cluster, or go custom gauges. Further, if you use the wiring harness from an ‘06+ Hemi, the harness has to be modified to ‘05 specs (among the other necessary changes).
The fuel tank mod is required because the Hemi fuel injection requires 59 pounds of fuel pressure. The ‘04 and prior TJ pump does not make enough pressure. You can solve it by swapping in an ’05-‘06 tank (which makes the 59 psi), but you can also install and ‘05 pump into an ‘04 tank with just a minor modification. A little trimming of the top ring on the housing and it works. The required wiring change is the same.
By far the best resource I have found for info on a Hemi swap into a TJ is the conversion guide written by Jim Bebe at Red Rock Off Road. I believe you can still buy it on their sight.