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2004 Dodge Durango 4bt

43K views 105 replies 20 participants last post by  artemis8me  
#1 · (Edited)
It has begun. Project Vehicle is a 2004 Dodge Durango SLT 4x4. It has 92,000 miles and a siezed hemi. Hemi-ectomy is underway. The current plan is to use a 47RH or RE with a 4bt and the existing transfer case.

I still need to purchase the transmission, electric vacuum pump
intercooler, otherwise all hard parts are acquired. I have numerous 6bt parts from a 53 block removed from my 99 Ram so i plan to set up the front of the engine similar to the dodge 6bt, dodge alternator, belt routing and ac compressor location etc.

Next steps:
Hemi-ectomy - there is very little room around bell housing, a real challenge to remove, plus engine is siezed so i am going to attempt to leave TC on engine when i pull since i can't spin crank to separate flex plate from TC, could be messy.
Motor mounts - have 6bt mounts, not sure if they will be part of the solution or not, current hemi mounts to the frame and IFS mount seem simple and could be part of the solution too.
Oil pan - plan to make a 4bt/hemi oil pan hybrid, space between front diff and pan is tight
Intercooler install - not sure what intercooler to use, or where it will be located exactly, i am sure i will be inspired at the time
Tachometer - plan to use hemi crank sensor and mount tone ring on damper, not sure if i will need cam sensor or not
Temp sensor - hemi temp sensor mounted in 4bt
Oil pressure switch - hemi oil pressure switch
 

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#99 ·
Intercooler is a 21" x 9" x 3" with 2.5" ports. Ebay find.


Centered between the frame tubes. It is angled forward, mounted to the bottom of the radiator and the top to the the front cross member above the bumper.


Adequate room on both sides for elbows etc.



I ordered a bunch of silicone boots from www.silliconeintakes.com, should be here next week.

I am going to abandon the factory airbox, there is adequate hood clearance to sneak a 3" pipe over the alternator and battery to put a cone filter intake behind the passenger side headlight.
 
#100 ·
With the 4bt pan sump forward, it interfered with the factory sway bar position by just a couple inches. I entertained the idea of finding another swaybar with longer trailing arms and mounting further forward. Instead, and $8 later, I blocked the sway bar mounts downward 3" on a couple pieces of 2" x 3" heavy wall tubing.





 
#102 ·
Attached angle iron to bottom of rad, bent tabs on intercooler to meet.



Fashioned 1" flat bar to attache to top mounting bolt on intercooler



Front View of final position



Top strap peeks out from under the bumper and attaches to front frame behind grille

 
#103 ·
Trans oil tube was fairly kinked and damaged. When i attempted to reshape it, it got worse.

Enter the electrician to save the day. I ground down the threads on a 1/2" conduit fitting slightly and then drove into the trans port. Fits nice and tight.



After one failed attempt when I bent the final curve the wrong direction, arrggh, I fashoined dipstick tube 2.0 and here are the results.





I plan to weld a support strap to the tube and attach a bell housing bolt.