Yeah, the exhaust manifold design on those was stupid. It concentrates all the heat on the back two cylinders.... so I do not find it surprising that they like to break manifold bolts..... The headers will solve that problem permanently.

 

Well got the donor motor out, all unbroken manifold bolts removed easily and successfully so, maybe that means the broken ones will too. Got to do a radiator in the wifes Durango tomorrow. Maybe Sunday we can see if the bolts come out.

 

I see no I made a mistake with me remflex gaskets. I ordered #6022 D port style, 09+

I'm trying to figure out which ones I need for this motor. I see a set listed for 5.7L Hemi BBK header but it doesn't list year range and the ports look oval shaped in the gasket. #6046, then it lists #4028 which im guessing is a BBK number as mine are 4009. The headers I have look correct to me, its just determining the gasket as I have square ports. I found #6011 which looks correct and says 03-08 hemi, perfect, then to follow is list hedman header pattern. I'm thinking these would still be correct but I would like to make sure.

 

Well we got the 06 motor out. Tore down for some inspection. At least half the rockers had 1/8" + lash. Strikingly no failed rollers, just stuck lifters. Possibly could've saved the motor with just a lifter replacement, but the weak compression was still a matter of concern. Didn't notice and stuck valves. This is my first hemi tear down but my experience so far says the oil used in this engine was cheap and far between. I haven't opened up the 04 motor yet as I'd like to keep it as clean as possibly. Once my top end gaskets show up I can swap over the valve covers, mount the exhaust and get it stuff back in. All the sensors so far look to be the same connectors so hopefully nothing there will need changed. (surprising for Dodge to use a connector style for 3 years straight). One thing I hadnt observed before and I'm not sure if this is an 04-06 issues or 1500-2500 issue but the 06 oil filter has a 45* stand off vs the 04 is straight down. The bolt holes appear to be cast in the housing. Once I drop th eoil and filter on the 04 I;'ll inspect more. I noticed this after pulling the engine so I did not compare clearance in the 06 before removal.

I was pleased but not, to see the 06 had a factory block heater. I didn't try to remove it as I figured I'll destroy it, I can add one later if I want. Are these a dry block heater? As the 04 hemi has the opening cast in, but there's no coolant?

I've been doing some research and I may rebuild the 06 motor and reinstall. I see there's a 392 stroker kit. Or even a 410. If I wanted to get wild I seen a post about a 500 kit. Since I wanted the 6.4 anyway, maybe I'll back door it. Not sure how the bore and stroke compares to an actual 6.4 current production but its just numbers. A nice cam and forced induction should stomp a factory 6.4 anyway .

 

Well, I'm not sure the sad life of the previous 5.7, the valve cover gaskets were baked rocked hard, shattered on removal. Insides of the valve covers were even caked with a char crusty material. I hated even putting them on this motor but not much option. Fortunately the replacement hemi looked much nicer under the covers. Tight last on all rockers was reassuring also. Grommet seals were still soft but dry rotted, crumbled on removal. Got everything mounted on the 04 motor. New plugs installed, sad to see, looks like he also spent money on plugs not to long ago. Not sure how Hemi's like Iridium compared to the old magnums, I got some Nickle ones, hopefully they get along. Wish I had purchased new coil packs not but I think it'll get by just fine. Other then having to remove the brake booster for 5 and 7 its no big deal to change later.

BBK shorties are mounted, I think we're ready to swing it home tomorrow.

 

Well, this morning is frustrating. Got an early start thought maybe I could fire it today yet. Setting the motor this morning it became obvious quite quickly these headers will not fit this chassis.

I guess I need to set out and find 4x4 2500 compatible headers which after searching slightly seems like they don't exist, at least for pre 09 motors. I found one set of JBAs someone mentioned fitment for 1500 megacab, the response was, with a few dents in the pipe which I find ridiculous or custom motor mounts to lift the engine. This, though still sounding ridiculous, had crossed my mind. Engine fan not in mind, would there be significant issues running the engine at this different angle. As far as trans pan, engine oil ect. The engine pan seems deep enough to be no issue, the trans pan is flat but I would assume the fill volume would keep it well covered. Driveline angle would be affected, maybe a trans space would also be in order in which case the plane of the engine/trans would be unaffected.

Thoughts, theories, ideas, I'm open to any and everything.

Might just put stock manifolds back on. The 06 manifolds had no broken bolts so they might be straight yet. Gives me time to reevaluate the situation without having this taking up my shop.

 

How much more clearance do you need??? If it ain't much, spacers would likely work.... raising the rear of the trans as well might be a good idea, it might also have the trans contacting the body on bumps, or when the engine torques over though too.... but, considering the angles these things are designed to operate at..... probably not really necessary....

 

In the lower picture the engine is about in contact with trans. I had not gotten the dowels lined up yet so back maybe another half inch. The primary pipe is resting on the weld section of the motor mount/frame and I would say for safe clearance minimum 1.5" between the motor mount and block plate. Maybe a little extra for torque room. Top picture, drivers side would go I think. Its just the passenger side, but both sides would need the spacers to keep the engine flat to factory positioning.

On summit the JBA 1961S-1 shows it fits 2500 4x4. and its visual that the cylinder 2 and 4 primary pipes go over top and back instead of down and back like these do so it optimistically correct.

Out of curisouty I rechecked the site I ordered these from (ebay) They show fitment for a 2500 4x4 but 1500 mega cab RWD only (I use 2500 ordering parts because. I'm not sure if this is a fluke or there is actually a difference between the 1500 mega and 2500.

Though purchased through ebay the seller was actually JCWhitney so I think return should be painless.

Summit doesn;t account for the 1500 megacab in the search options so Im defaulted to using 2500, but my above question now stands, is there a difference

 

From what I understand, the Mega Cab does indeed use the 2500 frame.... that is a LONG truck... needs the heavier frame.

 

That was also my understanding all these years