2007 Jeep Wrangler JK Build-Up

We have the engine mated to the transmission. The wiring harness made by Suier, Inc came in (along with a new computer). The harness fit perfect. The only thing to watch out for is that on the 07 and newer Hemi’s the crank positions sensor plug is smaller than what is on the harness. If you order a new sensor off an older Hemi (like 04), it will bolt right in place and has the right plug. I talked with Squier about this and they are already working on making another harness with the new style plug. To route the harness, you will need to remote the intake manifold, no big deal.

So…today we pulled the Jeep in the shop. So far we have removed the grille, radiator, condenser, O2 sensors, air box, drive shafts, and a bunch of bolts, hoses and other small parts. No surprises yet (other than how rusted the exhaust bolts are after so little time). We will post some pictures and VIDEO of the teardown, then a lot more pictures of the install.

We will be keeping close track of what parts are needed for this swap, and what parts will swap over from the 3.8 to the 6.1. Check back often for information on what you need for the swap and what to watch out for along the way.

P.S. We will be installing Superior Chromoly axles soon and put up info on that as well.

We just received the engine last week. So far we have the engine, transmission, engine accessories and starter. The main thing we had to change was the flywheel. The stock flywheel on the crate 6.1 was a different pattern than the one for the 545RFE that we have. Our transmission is a used 5-45RFE out of a 2004 Ram 1500 4wd. We ordered a new flywheel for the 5.7L, which mated to the 6.1L just fine. The part number for the flywheel (flexplate) was 4736604AA, it has four holes for the torque converter at 3, 6, 9 and 12 o’clock positions.