05 Ram Daytona 6.1 Engine Install

Hi All I have this posted on the Dodge Forum but thought some of you might like the info

05 Ram Daytona 6.1 Heart Transplant


After months of working on this project it is nearing its end. I drove my 2005 Ram Daytona with the new 6.1 engine for the first time today, It sounds and runs great. I am working on the final tunes with Sean at Hemi fever Tuning before I cut it loose.
The engine started as a new 6.1 complete crate engine. Initially I was going to build a stroker engine but decided I really wanted just some super dependable HP for my tow rig.

Prior to the engine Change, I did the following upgrades
Transmission
545RFE was fully overhauled with upgraded components by Don at Nor Cal Transmissions in Santa Rosa, Ca. He went all out on the trans including all the available billet upgrades, a new stall Converter, upgraded ATS Trans Pan with 4+ qt additional capacity.
I replaced the small transmission cooler with the large factory cooler, a perfect fit
Driveline
(2)New Forged U joints were installed.
Ft & Rear Differential
The Front diff received the new PMI aluminum diff cover with a filler and a drain. Redline Synthetic Oil
The Rear diff carrier was replaced, all bearings replaced and I installed a new Eaton Tru Trac, helical gears Posi. I love that thing, no chattering! I used Redline Synthetic Oil , Note: you must use the NS oil with no additives for the Tru Trac diff.
I upgraded the axles to new Moser Engineering Axles
The Rear diff cover was replaced with a MAG HI TEC. I love it, no glue, it has an Oring and has a dip stick and drain plug and it holds1.5 qt more oil!
Cooling
The 6.1 engine has no manual radiator cooling fan so prior to the swap I bought the Derale #16795 Controller and the #16835 Dual Fan assembly. The cooling fans assembly fit the Stock radiator perfectly. I made new upper and lower brackets so it would fit into the stock radiator support and mounting brackets. ( The fans are on the noisy side but do a great job)
The old 5.7 fan shroud used to support the washer tank and the coolant reservoir. I found a vendor on Ebay (j.a.c_specialties )that makes some incredible polished Stainless tanks and he made me some custom (2) 4” tanks for the coolant and the washer fluid and a 3” tank for the P/S reservoir. These are the nicest high quality products you will ever find anywhere !

The New 6.1 Engine
I tore the brand new 6.1 SRT 8 all the way down and made the following upgrades to the 6.1

I retained the Stock bore and stroke
New Forged Mahle 10.3/1 pistons
New Forged Manley H beam rods with 7/16 bolts
JBA Headers, JBA-1961S-2JT Titanium Coated short ( made for D port Heads and a perfect fit )
Clevite CL77 H mains and rod bearings throughout
Melling High Volume (Adjustable Pressure ) Oil pump
Ported and polished Heads
Ported and polished intake runners
Comp cams valve springs and retainers
Comp cams hardened pushrods
ARP head studs
Comp Cams Ca # 112-501-11

The engine sports all factory 6.1 Accessories, Alternator, AC Compressor etc. The fit for the engine was never a problem aside from I had to make new trans cooling lines ( Super easy using Russell Fitting)
I did use the Factory SRT 8 intake, 6.1 Injectors, 6.1 Coil Packs

The real issue was doing a pin out map of the wiring harness and making a new harness with parts from the 6.1 harness that came on the engine and the 2005 5.7 harness. I was a tech for most of my life so the task was not difficult just time consuming. It took me about 8 hours total time.
I bought the OE German harness wrap and I found some really great silicone high temp wrap. Both of these are super high quality. You will never have any black tape glue seepage issues.

On engine controls and sensors I used the
(Original 2005 5.7)
Coolant temp sensor ( uses the stock 5.7 connector)
Oil Pressure Switch ( uses the stock 5.7 connector)
Air Temp Sensor ( uses the stock 5.7 connector)
A/C High Pressure Switch ( uses the stock 5.7 connector)


(6.1 SRT)
Map Sensor ( Requires harness upgrade to 6.1 Connector)
Throttle Body( Requires harness upgrade to 6.1 Connector to increase length )
Crank sensor ( Requires harness upgrade to 6.1 Connector)
Cam Sensor ( Requires harness upgrade to 6.1 Connector)
Knock Sensors ( Requires harness upgrade to 6.1 Connector)
Alternator( Requires harness upgrade to 6.1 Connector, I also made the alternator battery power cable run through the harness to the back of the engine to the starter to clean up the engine bay)
A/C Compressor ( required longer Low & HP Hoses, I cut the old hose crimps off of the OE fittings) The local Napa Auto Parts in Petaluma Ca did a great job! I evacuated and charged the AC.
P/S Pump ( I bought Russel HP Fittings and made the HP hose. NOTE: The 16mm fitting on the PS rack requires a modification or it will leak.)
Belts & Hoses
Upper Radiator hose (2006 jeep grand Cherokee SRT8)
Lower radiator napa # 8037 ( it is a molded hose and a tight fit on the WP)
Heater hoses napa #9808 & # 9809
Fan belt dayco #5060815 6pk2070
Air Flow
I had the Mopar Cool Air kit on my old engine. I was surprised that with the 6.1 it actually fit even better. I had to install a new rubber support bracket and slightly angle cut the end at the throttle body.
Exhaust
I towed the truck to A1 Mufflers in Santa Rosa and Gary did some of his best work on my truck. All of the support mounts he hand made from Stainless and fit into the supports from my original Borla exhaust brackets.
I went with
(2) Magna Flow HM 3” cats
(4) Quad Bosch O2 Sensors
2.5” stainless pipe throughout
(2) 2.5” Stainless 3/8 flanges
(1) Magna Flow X PIPE
(2) Borla Stainless mufflers
(2) Borla Tips

Thanks for everyone’s input along the way. If you have any questions let me know

Rob




__________________
Rob
Original Owner 2005 Ram 1500 Daytona, Quad Cab, GoMango.
Hidden Warn 9000i winch, built 545rfe, Trutrac diff, JBA headers, stainless exhaust
New Built 6.1 SRT engine as of 9/20/15

Pics or it didn't happen!

pics are in my album

Daytona#4595 said:

pics are in my album

Click to expand...

Then I rescind my comment...

Did you do this swap yourself? Was it pretty straight forward for the most part?

I did everything myself from A to Z!
I think the wiring harness will be the toughest for most people. I made mine from the 6.1 and my 5.7 harness parts. It requires that you be able to do a pin out of your harness and know what parts you are keeping and or replacing or moving. As well as great soldering and heat shrink abilities.
Things like adding the electric cooling fans and making brackets for the new tanks for the Washer Solvent, Coolant Reservoir and PS Reservoirs were straight forward for me.

One of the companies I spoke with told me the 6.1 rear cranks needed a spacer. I measured all and the specs were the same as the 5.7. I had to use the 5.7 flex plate, the 6.1 converter has a different bolt pattern. Also I found the 6.1 crank had an insert in it that I had to remove, similar to a pilot bearing reducer spacer. Maybe the 6.1 converters have a smaller support on the ft.

PS,
I went through several trial and errors on the headers. I wanted to use the SRT stainless headers but they will not fit. I had read that the early Jeep SRT stainless headers fit, but I was unable to find any. I also tried the new Jeep 6.4 manifolds, no go.
I called JBA headers and talked to an engineer and he told me he was sure their headers for late model D port engines would work and they did. A perfect fit with no mods. I added a heat small shield to keep heat off the AC high pressure line on the drivers side.

I seen you had shorties on there an how the 6.1 have a different port, a guy on HTC did a 6.1 swap in his 08 a few months ago an recently put the jba longtubes in an is happy.


I would like to start gathering some forged internals, crank, another block etc for my old girl. She's $585 from being paid off! Lol

My old 5.7 has a smaller oval exhaust port and I want all the HP I can get!
The 6.1 has a larger exhaust port in a D shape. The flat part of the D is down.
The tech at JBA said that the newer hemi engines use a D port and he was sure the shorties would fit. He was unsure if the long tubes would fit my truck, I was just happy to get some that fit.
The shortie headers I used fit a late model Ram 09-14 1500

Are you planning a 6.1 or pump up your 5.7 ?

I have a lot of new 6.1 parts that I am going to sell if your interested
All parts are new unused from my 6.1 crate engine
6.1 Stk pistons, rods with rings & rod brgs
6.1 SRT Cam
6.1 Valve springs
6.1 head bolts

I may have some other items I will check and see

congrats on the build/swap!! you're in Norcal? I would love to do a meetup someday and take a look at your mean machine in person!! a couple (Hemitruckclub) of us are in a car show this weekend at Newparkmall in Newark. Maybe we can plan a meetup at the track (Sac or Sonoma) someday...

do you have the specs for the cam you installed?

I would love to meetup some time I am about 20 min North of the Sonoma racetrack.

Here are the Cam Specs link
Comp Cams Ca # 112-501-11

112-501-11 - Xtreme Fuel Injection (XFI


Rob

You mentioned something that has me a bit confused. You said you wanted this for your " tow rig" but you said also that you installed a new "stall converter". If you meant "high" stall converter they are not generally used on "tow" vehicles. They use a "low" stall converter.

Yes it has a high rpm stall converter. Having a high rpm stall converter does not prevent you from towing or driving normally. If you want to power-brake and build up engine RPM before take off it allows you to take better advantage of your cam and get better take off power when needed for a heavy tow or a large Burn Out.

My next project with my ram is a new 6.4 based 426 Stroker engine that I just finished building over the winter. It is based off a new Hellcat block with all of the top shelf HP parts I could manage.
Additionally, I am now buying parts to upgrade from my 545RFE to an 8HP70. I spoke with Russell at Sound German Auto and he recommends the 14-17 8HP70 as it will bolt up to my NP241D transfer case. With the new trans I will have to ditch the 456 gears front and rear and drop down to 3.55's. I am leaning towards doing the trans and new diff gears first as the new engine would probably kill the remaining life from my built 545RFE.

Attached are a few pics of the engine, I sprayed the front cover, water pump, valve covers and heads with Cerakote. The new Holley High Ram is powder coated in Silver and then Purple, It looks Awesome.