5.7 Hemi swap

Well hell...what can I say. I'm alllllll the way to the finish and wouldn't ya know it, a procal problem.

Here's what happened. I have everything together and ready to start so I plug the procal in and go through the sequence to program the VIN. This has to be done otherwise it won't start. First try, no dice. Try again. Still nothing. Dangit. Try 8 more times nothing. So, I go to sleep more frustrated than eunich in a whore house.

I called AEV this morning and actually spoke with the owner on his cell phone. He had never seen this happen so I end up speaking with one of his engineers. Apparently I should not have "restored" the procal prior to the swap. Doing this permanently voids the VIN from that procal and the procal can't be used on that vehicle again. Go figure. He apologized that the directions don't have this information in it. He said that I would have been just fine leaving it with the modified information in place.

I "thought" that I was being proactive in returning the JK's original PCM to stock. Lo and behold, the VIN isn't just stored in the PCM. It's also in another area. So, I effectively wiped my procal out and it can't be used again until it's reflashed. Nice eh?

The good news is that AEV's customer service is very good. They are trying to get me a procal locally and if not, I'll have one overnighted to me.

So until then, Mr. Blue Balls signing off.

That sucks Balls!!!

Damn dude...i would be furious...One question...How could you go to sleep? I know I would be driving to where ever they have them at to go buy one thats for damn sure lol

..::Ryan::.. wrote:

How could you go to sleep?

Crown Royal. Lots of it.

..::Ryan::.. wrote:

Damn dude...i would be furious...One question...How could you go to sleep? I know I would be driving to where ever they have them at to go buy one thats for damn sure lol

Did you miss the part where he said that his jeep wouldn't start......

He would have to take a cab or hitch a ride.


BigT
it will be a distant memory before you know it - and every time that you push the pedal and something actually happens that extra day wait won't even come to mind.

Have another Cuban (cigar....) and vodka!

Thanks everyone. Ron, you're right. It'll all be over with before too long. I think it would irritate me more but right now work has me slammed until Friday evening, which should be about the right time when I can get back to things.

Here's a quick update for everyone. I got my Procal on Friday but unfortunately, the dash gear selection indicator was saying that I was in R when the floor shifter and transmission were in P. I did just about everything you could think of. I pulled the transmission valve body and replaced the solenoid pack ($300), checked all the grounds, pulled codes and then retraced a bunch of wires to ensure proper hook up and connection. This went on until Sunday night.

Another JKO member is doing a hemi swap at the same time so we've been speaking about our experiences over the past two weeks. He called last night and asked me to check a diagnostic port (near power brake booster) that's on the AEV harness. It was good but wait...C100, 34 way connector is NOT COMPLETELY PLUGGED IN. WTF, over! I plugged it in and made sure the cam lock was completely activated and voila no more R on the dash. Heck, I don't even have any indicators on my dash now. I think this is b/c the PCM is not programmed to the new VIN. However, I don't have any trouble codes. Yippee!

So, why haven't I started it? The Procal that was shipped to me is DEAD. It does nothing. AEV has a few dead ones floating around and it seems that I was lucky enough to get one. Go figure right? Tito's vodka helped me soothe that ache.

Now all I need to do is wait. Again.

That sucks, but I bet you're gald you found the problem.
Maybe you can come out to the install party on Saturday and show off that Hemi. I am sure you'll have your procal in by that time.

thebigtman wrote:

It was good but wait...C100, 34 way connector is NOT COMPLETELY PLUGGED IN. WTF, over! I plugged it in and made sure the cam lock was completely activated and voila no more R on the dash. Heck, I don't even have any indicators on my dash now.

I'm seriously looking forward to checking out the finished product one of these days. But that part right there reminded me of a (much smaller) similar problem I had with my front E-Locker not engaging. Turns out the plug had been torn out at some point. Plugged it back in, and it worked great

I wish I had news that the hemi fired up tonight but I don't.

This morning I ventured out to my shop while I was on a break from work and opened up my dead procal. I figured that I've got nothing to lose. Amazingly, I found one diode that wasn't connected. So, what the hell, solder it up right?


I soldered it but still no joy on the Procal. :thefinger: Call Jordan at AEV. He advises that I put the 3.8 PCM back in the Jeep. So I put it back in the Jeep and do the hokie pokie and go to try it out. I program the procal to mod the tire size. Success! Woohoo, now we're cooking. I try to pull the codes and accidentally move the key too far and I hear the starter cranking. Oh chit, turn it off, turn it off (all the while remembering Jordan telling me NOT to start it with the 3.8 PCM installed)! At least I know the starter works right? Next, swap out the PCM for the AEV PCM without disconnecting the battery. Program VIN. Two honks. Success! Program TPMS to off...two honks. Program tire size...two honks. All right. Now we're getting somewhere.

At this point, I feel like an 8th grader that's successfully gotten to second base with his date. Move on to see if the dash cluster reads correctly (I'm moving to third base). Nope, still in R. Dangit back to the drawing board!

The funny thing is that if I unplug the AEV diagnostic port, the shift interlock doesn't prevent me from shifting out of P. If it's plugged in, I can't move the shifter from park. If I unplug the 34 way connector above it (called C100), the radiator fan kicks on. I'm at a loss now. I went over every single connection again tonight...TWICE. I'm starting to think it's the PCM or something with the JK electronics got screwed up when I did RESTORE with the Procal. The transmission is definitely in Park. I've counted the detents and even had the valve body out again. The good thing is that AEV is responsive to my calls/emails and I have the ear of the top guys there. I sent them a lengthy email this evening detailing all my checks and symptoms. I'm sure I'll speak with them again in the morning. I've got to get something going soon. My wife goes in for surgery on Friday.

Since the engine cranked with the PCM from the 3.8 I'm thinking there's an issue with the AEV PCM. I know that it's a long shot that the PCM is bad but I've done all I can think of at this point. It's really the only viable alternative to try.

I shot a few photos of the transmission to illustrate the solenoid pack that I referred to a few posts back.

Here's what the trans looks like with the flat pickup filter removed. You'll need a T25 bit to remove the flat filter and work on most internal parts in the 545rfe. Here, you're looking at the valve body.


After you remove the valve body, you'll see this on top. This is the solenoid pack.


When you replace the solenoid pack, MAKE DARN SURE this arm fits in the saddle on the solenoid pack. This arm moves to tell the solenoid/PCM your gear selection. You need to physically push the arm on the outside of the transmission to P if you have the solenoid pack in the P position for reinstallation.


Trans filter and spin on filter for tranny cooler lines. FYI, the napa filter pack didn't have the spin on filter with it. Autozone's filter kit had both but no gasket. Mopar says no gasket and use RTV but I'm a rebel so I used the gasket anyway.


Maybe it doesn't run b/c I put the stickers on first?!


She's dying to get out of here


Another night without the JK breathing fire.


I'll keep ya'll updated as I know more.

if you don't get it figured out soon ya might call tony at hotwireauto.com

he has probably forgot more about hemi swaps than aev ever knew!!

Good copy...thanks.

IT RUNS!!!!!!! The new PCM from AEV solved my problem. I am the only one to ever have a bad PCM from them. Go figure!

I have a leak around the oil filter adapter so I've got another one on order. I don't want to take a chance with it.

thebigtman wrote:

IT RUNS!!!!!!! The new PCM from AEV solved my problem. I am the only one to ever have a bad PCM from them. Go figure!

I have a leak around the oil filter adapter so I've got another one on order. I don't want to take a chance with it.

and your in here typing.............wtf!!!!!


we demand burnout videos!!!!!!!!!!!!! NOW!!!!

LOL! I know I know...but it's not for the lack of wanting.

Believe me, I want to do that video but I found a crack in the oil filter adapter so I'm swapping it out. I didn't spot it earlier until it pressurized under startup and caused a leak by the oil filter.

That is sweet! Congrats man!

thebigtman wrote:

LOL! I know I know...but it's not for the lack of wanting.

Believe me, I want to do that video but I found a crack in the oil filter adapter so I'm swapping it out. I didn't spot it earlier until it pressurized under startup and caused a leak by the oil filter.

THAT ONLY TAKES 4 MINUTES TO FIX.........

http://www.jbweld.net/products/jbkwik.php









I will be here patiently awaiting said video..............

redneckhouston wrote:

I will be here patiently awaiting said video..............

x2 on that

X3 on the video. What ya waiting for Timmay!!!

thebigtman wrote:

LOL! I know I know...but it's not for the lack of wanting.

Believe me, I want to do that video but I found a crack in the oil filter adapter so I'm swapping it out. I didn't spot it earlier until it pressurized under startup and caused a leak by the oil filter.

Heck, won't that leaking oil on the ground just make the burn out easier

dude, i have hemis and jeeps everywhere... if you need a part, just let me know! (just kidding!)

I finally got the last few parts I was waiting on. I didn't get started with anything until late this afternoon. All is well with the wife. Thanks for all the well wishes.

Last, and certainly not least, I promised video. Here it is! Hopefully I'll get some more video up once it's daylight and I get a chance to smoke the tires a little. No burnout shots for now.

I've got about 5 miles on her so far. No leaks, no codes, all is good. Oh, I made sure that I wore my sandals for extra safety too!

YouTube - 2008 Hemi JK Unlimited

That is awesome. Sounds great

Its Alive..... ITS ALIVE!!!

You, my friend, are living the high life!


Enjoy it bruddah!!

Ha Ha Ha I got to ride in it!!!!!