JKU Hemi Swap - Reference Guide & Swap Info

Rear Sump Oil Pan Swap
Since my motor is an LX-based crate engine, the front-sump pan needs to be swapped out for a rear-sump style. My crate motor came with a Mopar Rear Sump Oil Pan Kit, Part# 77072450AB. If your engine came from a truck, you'll already be set up for a rear sump and won't have to worry about anything.
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The crate motor came pre-filled with engine oil, something I was NOT expecting! The only reason I thought to check this was because over the weekend, I was putting gear lube inside my 1-tons, and when I went to fill the front Mopar UD60, I was shocked to find that it was already full! I'm glad that I check it before flipping the engine around or pulling the pan, as this would have been a spectacular mess on my garage floor...
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It's a lot easier to do the pan and adapter swap while the engine is flipped around. In anticipation of the arrival of my Speedway Motors BlockDock Lift plate, I pulled the intake and put some tape down over the ports to keep crude and dust out. Even though the lift plate covers the intake ports, I figured this was a good bit of insurance.
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You can see some more engine-related items once you get the intake off. The red arrow above shows the VVT control solenoid; all 2009+ VVT engines will have this. The blue arrows (above image) are pointing to the MDS-delete plugs. If this had this been a take-out engine from a SUV, Ram 1500, or car, these would be MDS control solenoids and would have some wires attached (green arrows below):
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All modern Hemis have MDS, so if you're getting a used engine, it will likely have MDS. The only non-MDS engines in the current line up are the 6-speed (manual trans) Challengers and all Hellcat 6.2L equipped cars. The earlier Ram 2500/3500 with a 5.7 were non-MDS, but you haven't been able to get a 5.7 L Ram HD truck for quite some time.

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One of the things I least look forward to on engine work is flipping the motor on the stand. I'm a big guy, and am plenty beefy for this, but after having a cylinder head almost crush my foot at the ripe ol' age of 15, I've hated it ever since. What had happened was the "pin" that keeps the center plate stable wasn't in, and as I started torquing the head bolts down, it spun around and dumped a 906 casting right where my foot was. I was able to move my foot fast enough to prevent it from getting crushed by the leading edge, but it still gave me a nasty bruise (and likely a broken toe or two).

Thankfully, this flip went uneventfully and I got to moving on the pan and filter adapter swap. The pan is easy to remove, and the instructions are easy to follow, just keep in mind that the rear sump pan will require you to swap out one of the middle main bearing cap bolts (yellow arrow) and swap it with a double-ended stud (included in the kit). This is because the rear sump is long and the double-ended stud offers a location to bolt the pickup support to.
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One quick tip here - one step that is easy to miss during the installation is the removal of the dipstick plug in the block. You can see the removed plug in the below image, on top of the block lip just above the hole where it came out of. The front-sump pan has a dipstick that goes through the pan itself, but the rear sump pan utilizes a hole in the block. Again, if your engine is already setup for a rear sump, this isn't a problem, but if you're going to use an LX block, you'll need to remember to punch this plug out BEFORE mounting the pan itself. It is easy to do with a simple drift punch and a few light taps with a hammer.
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The install instructions are simple, just follow them and you'll be fine. The installation finishes with the installation of the dipstick through the block hole that you opened up with the removal of the plug mentioned earlier. One issue I ran into was that the dipstick was hitting the Mopar SRT Manifolds:
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To fix the issue, I simply used my hands to exaggerate the bends a bit more, then put a small bend in the tab that mounts to the exhaust manifold stud:
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45° Oil Filter Adapter Installation
The oil filter points down in stock form and will typically be smashed by the axle during up travel, necessitating the use of a 45° oil filter adapter. Mopar, Holley, and others offers a kit. I found a Mopar one for a reasonable price and ordered it while I was getting some other supplies needed. The kit is sold as Mopar PN 77072447:
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You're going to need a 12mm Allen Wrench socket to remove the factory filter adapter (shown below mostly unthreaded)
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Installation is a breeze - lube up the O-ring seals with some clean oil, thread the bolts in place, and torque them to 9 ft-lbs.
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Frame Prep - Removing the 3.8L Engine Frame Mounts
There are many companies that make new frame mounts to facilitate Hemi or LS swaps. JSS offers both weld-on style mounts and "bolt-on mounts". The former requires you to cut off your OEM 3.8L frame mounts, while the latter allows you to keep your OEM frame mounts in place. Both are good options, though the "bolt-on" mounts come at a much higher cost ($295 vs. $750) and make an even tighter engine bay even more so. They also require you to shave some accessory bolts down (e.g., the hold down for the oil dipstick, and the knock sensor mounting bolt), and they also make replacing the knock sensor impossible with the engine in place (not that OEM knock sensors go bad all that often). Not only that, the bolt-on mounts also limit what exhaust manifold/header options you have available to you.

I'm going with the weld-in mounts for my swap to keep things simple and have better overall clearances. I also like the fact that they utilize OEM 5.7L WK2 motor mounts - for me, having off-the-shelf replacements is always a win in my book. To get started, I used a cut-off wheel to work around the edges, cutting into the weld and trying to stay out of the frame rail. For the driver's side, you'll almost certainly want to remove the factory steering shaft from the firewall to the steering gear. Since I'll be swapping my PSC box out soon, and since I'll need to clearance the firewall for the steering relocation bracket, I was going to have to do this soon anyway...

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The OEM frame mount is a two-part assembly welded together. There's a saddle on the upper part that holds the transverse bolt from the motor mount itself. Then there's the base/strut that provides support to the saddle from below. To remove, I cut the two small sections that hold both pieces together. Doing so leaves the upper saddle portion only welded to the frame at the upper seam. A few whacks from below with a BFH quickly bends the saddle upward, allowing you to see-saw it and crack the weld loose from the frame:
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The lower portion is a little harder, since it's welded around the radius of each lower corner and edge. I focused a little bit of time on the leading edges on both sides, and then a quick whack with the BFH gets the edge loosen. Once the leading edges are loose, you just keep see-sawing the mount back and forth (I used the BFH and a 12" adjustable wrench) until it snaps loose from the frame. After I got the mounts off, I used a flap disc and grinding wheel to clean-up the frame rails:
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Depending on your time frame and work speed, it probably makes sense to put a good coating of primer and possibly even some paint on the frame rail until you're ready to weld on the replacements.
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I always use Seymour PBE Weld Thru Primer for stuff like this:
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PSC Motorsports High Flow Pump
As typical with nearly every subject on the internet, there is a lot of misinformation on what is needed for the JK with a Hemi swap, and what PSC pumps work are no exception, so lets try to clarify some of it. I ordered PSC PN: PK186-HEMI, the SC Power Steering Pump and Remote Reservoir Kit for 2007-18 Jeep JK with HEMI Conversion (6 Rib Pulley).

The kit includes the following part#s:

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It seems like there has been a slight change in the pump that is currently being supplied by PSC. From what I've been able to find, it looks like PSC used to supply the SP32362 pump, which was originally for the 97-02 Jeep 4.0L. This PN is DISCONTINUED, and has been superseded by SP33362. I received the SP32332. I think the main difference is whether or not the mounting holes are drilled or threaded, and the orientation of the return and supply ports.
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One other thing that has changed appears to be that now PSC is shipping their "Hemi" kit with a smaller diameter (5") pulley. From what I can tell, this was originally a 5.75" pulley but they have since decreased the diameter for clearance. This is very likely due the fact that the original Hemi swaps were using non VVT engines. With the transition to VVT engines, as well as the common use of "LX" based (car/SUV) engines, they had to slightly tweak things.

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My 345 Crate Hemi is based on the "2015+ Challenger" and is not set up for power steering, though Mopar Performance used to offer plenty of kits to make it work with older vehicles. You can see the small "tower" mounted to the cylinder head that allows you to run a small, grooved idler pulley

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I installed the pump with the included spacers. As typical with PSC, their instructions are $hit and there's no good resource online. So, with good bit of additional digging, bothering Todd at JSS, asking a buddy who had done this swap (but with a 6.4L), and posting on the JSS Facebook Page, it appears that PSC designed this pump for use with Non-VVT engines, which with the included spacers, works well on the newer VVT Truck engines. Unfortunately, as you can see above, it leads to two main issues. First, it hits the belt tensioner. Second, it's also about 1/2" too short...

A little fun fact - nearly all 2013+ Hemi's use an electronic power steering pump, instead of a belt-driven pump. When you couple the fact that the LX engine was released in 2011, there is a small "sweet spot" for options: the 2012 Challenger. This is the exactly why JSS uses this pulley for LX-based JK Hemi Swaps. The Part# needed is: 68032253AB.

According to JSS, I could use the PSC-included spacers and install the Mopar pulley listed above. However, I decided to try a different route. PSC offers a JL 392 Hemi pump kit bracket. Despite having sent them an email a few days about fitment and applicability, it has been the typical PSC crickets. Thankfully, someone on the JSS Facebook Page ran into this same issue and confirmed that the bracket works perfectly to align the belt on my crate/LX-based engine. It also locates the pump up slightly higher, which helps clear the frame and PSC Big Bore Box I will be running.
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The bracket should arrive this week, so hopefully I can get this confirmed and mounted up this weekend...
 
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