[mystycal]

Mine burned up just emptying the tank, that fuel pump more then likely will burn up bro.

 

[GreenSound]

glitchyboy - good to see your progress!!! I've been busy doing suspension/tires on my rig and ignoring my dying 4.7L - your build looks pretty promising! I need to read the build again to really catch the details - I was always curious how the 4BT would clear the front diff.

I do say having the 4.7 (pre 2008) would really have made life easer, as it has a cable throttle!! I'm also thinking of a manual swap if I go this route some day. Any idea of power you're looking to make with the 4BT?

 

[mystycal]

I had to notch my Pan to clear the diff in a 02 ram 1500, Dakotas durangos all need to be notched for clearance issues. GO TALL 4BT!

 

[gitchyboy]

I've got some pictures further back in the thread, I heated and hammered the pan, didn't have to cut, front sump interferes with the sway bar but I think an 05 Ram sway bar will work, it's a bit wider but also has longer trailing arms so I can move the pivots forward and get the cross bar front of the pan

 

[gitchyboy]

PS Pump and Reservoir

After being unable to get the Durango PS pressure port to thread into the 4BT pump, I tried to identify the PS pump port thread, I realized the Durango power steering pressure hose WILL thread into the 4BT PS pump. I guess the angle was preventing the thread to start. I had to bend the steel portion of the pressure hose to clear the motor mount and the body of the pump. DIRECT FIT.

The divorced reservoir is from an F800 or something similar. I mounted it to the vacuum resrevoir on two existing bolts. There is a fairly large space beside and beneath the vacuum reservoir and is accessible from the top with some of the plastic valance trimmed back along the firewall for access.

The return port on the pump looks to be a 1/2" hose barb, the entire durango system is 5/8" so the return will need to be reduced to fit this port, I hope it wont restrict. I was thinking I could tee the return into the reservoir to pump fill hose if the 1/2" port is too restrictive.

 

[gitchyboy]

Gear Indicator version 2.0

Decided to go old school, I removed the upper part of the valve body including the shift mechanism and electrical connection and built a box for them. I plan to slave this unit to the shift arm on the transmission with a cable. For now it will stay in neutral. Digital gear indicator readout works! There is plenty of wiring harness length, so if the location on the inner side of the frame rail is too close to the front driveshaft I may mount on the outside of the frame. The valve body is fastened into the box through the back with the same screws that held the valve body together.

 

[gitchyboy]

Now that all the mock up fitting is done, I removed the transfer case and transmission, installed the flex plate, and torque converter. The Durango had a cast iron bracket that went from the top-rear of the diff back to the bell housing to keep the diff from wobbling in the rubber mounts. With the drivers side dodge/cummins starter location there is no room for the brace. I installed a piece of flat iron from the top front diff mounting bolt and attached it to the front left engine mount.

Hope the picture does it justice. Simple but took the wiggle out.

I am now doing final install of the pickup tube and oil pan.

 

[gitchyboy]

Rad hose puzzle solved.

Top Hose is made of part of the bread van hose that came on the engine on the left of the photo, simple 90 deg, the right half is part of the lower rad hose for a 4020 John Deere, joined by a 1.75" piece of aluminized exhaust pipe.

Bottom Hose, upper portion is a 1999 dodge cummins lower rad hose rotated to point down, the lower portion is the lower rad hose from the 04 Durango Hemi, joined with a 2" piece of aluminized exhaust pipe. Sorry for the rotated picture.

 

[gitchyboy]

KDP Killed

 

[Motohead1]

how thick is that flat iron brace you made for the front pumkin? If you still hanging from the stock dakota mounts there can be a good bit of roll force placed on it. Your making some head way caint wait to see it running.

 

[gitchyboy]

how thick is that flat iron brace you made for the front pumkin? If you still hanging from the stock dakota mounts there can be a good bit of roll force placed on it. Your making some head way caint wait to see it running.

Its 3/16" x 1" flat bar, I had wanted to use angle iron for strength, but the space was pretty tight, it is about 10 3/4" long center to center hole and isn't angled at all, I am hoping it is strong enough.

 

[gitchyboy]

AC Lines

I was able to bend the Durango high pressure line straight and feed the line over to the passenger side of the vehicle. It is the same size as the high pressure line off the 95 ram diesel compressor, joined with a brass compression fitting.

The Low pressure line on the Durango is 3/4" and the low pressure line on the 95 Ram piping is 5/8", looped the rubber portion of the Durango hose to meet the Ram piping and adapt them together with brass compression fittings.

 

[gitchyboy]

how thick is that flat iron brace you made for the front pumkin? If you still hanging from the stock dakota mounts there can be a good bit of roll force placed on it. Your making some head way caint wait to see it running.

I was looking at the driveline rotation, and the torque in forward gears will pull on the strap. I am guessing it will stand that force without issue, I am guessing but hard reverse torque or rocking back and forth if I get stuck may be were I should be most careful.

 

[Motohead1]

I was looking at the driveline rotation, and the torque in forward gears will pull on the strap. I am guessing it will stand that force without issue, I am guessing but hard reverse torque or rocking back and forth if I get stuck may be were I should be most careful.

Correct if you were a manual trans I would be more concerned as engine braking say down a hill might twist it.

 

[gitchyboy]

Hadn't thought of that

 

[gitchyboy]

This seems to be a theme with my projects

One clamp short of a 4bt

 

[gitchyboy]

Haven't seen this since 2014

 

[gitchyboy]

This part of the project seems like Christmas

 

[gitchyboy]

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.

 

[gitchyboy]

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.