Performance is a word that means so much to so many people. Ask any car guru to describe performance and he's likely to come back with a million different supercharged or high-boost engine upgrades that he would love to have. Ask the same question to a Jeep guy and he'll probably mention things like coilover shocks and long-arm suspensions. To us they are both right. For most veteran auto enthusiasts, performance is something that is sought after throughout the entire vehicle.
It's with this idea of performance that we've decided to put our '99 Dodge Durango project vehicle, dubbed the Heavy Metal Mudder, back under the knife for a serious powertrain upgrade. If you've followed our series of the build (the fifth and final part was in last month's issue), you'll likely note that the monster Mopar is already complete with a custom multilink suspension, 21/2-ton Rockwell axles, and 44-inch Boggers. It is powered by the factory 5.9L engine, 48RE transmission, and NP242 transfer case. We clearly have everything from the framerail south beefed up, but the factory stuff just doesn't have the high performance and power we're itching for.
1. We chose to remove the...
1. We chose to remove the hood for better photography lighting and increased visibility of the firewall. Though removing the hood isn't a must, it will all but eliminate the little dark cavities that hide those hard-to-see firewall clamps and bolts.
So now we find ourselves back east in Wilmington, North Carolina, at National Speed, a place that specializes in high-performance engines and tuning. From twin-turbo Nissan 350z's and classic muscle cars to coilover suspension systems, National Speed's experience with the high-performance aftermarket world made it the perfect choice for the next stage of our Durango build.
By this point you're likely wondering what high-performance powerplant we have in store. As much as we would like to go ahead and give away how we plan on squeezing over 500 ponies under the hood of our high-rise Durango, we won't spoil the surprise (though there are some good hints in this story if you read between the lines). For this issue we focus on getting the old parts out and begin the preparation for the new terra-dominating powerplant.
2. Ripping out the factory...
2. Ripping out the factory engine means unplugging every vacuum line, breather, and electronic widget that's attached to and thru the firewall. We suggest using a box of Ziploc bags and a Sharpie to keep track of all of the small parts. Though we'll likely not use too many of the factory pieces, sometimes a basic fastener, clip, or plug can be reused to save time and expense.
3. The engine control module...
3. The engine control module and wiring harness are two incredibly delicate and expensive parts that you don't want to lose or damage. Since we are swapping in a completely different engine we went ahead and yanked the old bundle out. Be sure to keep all of your old harnesses and controllers with the engine so if you ever want to swap it into another rig you have all the pieces.
4. The original 5.9L coupled...
4. The original 5.9L coupled to the stock 46RE transmission has served us well and is a decent powerplant from the factory. Though we looked at throwing a turbocharger on the engine, we're simply searching for more than a little boost. And as we didn't expect our Durango to be a Baja racer, we felt a little more power to spin our 44-inch Boggers was definitely warranted.
5. With everything peeled...
5. With everything peeled out from under the hood we wrapped the remaining parts and started cleaning. It's amazing how much dirt and grime can build up over 10 years of street use and a few months of mud bogging, and we're sure glad the truck is no longer purple!
6. Since our new engine will...
6. Since our new engine will be pushing out around 540 hp and 580 lb-ft of torque, it should have more than enough muscle to propel our Heavy Metal Mudder through the dirt. Though we're not ready to give away all the engine details just yet, we figured we could at least show you a little low-budget engine dress-up.
7. No teardown is complete...
7. No teardown is complete without a little fire action. And since using the old engine mounts isn't an option, we broke out the torch and made light work of the factory framerail tabs.
Full speed ahead
Most engine swaps require a little firewall modification. This one requires a tad more. Stay tuned as we try to squeeze in over 500 ci of engine and start work on our custom firewall, engine mounts, and whole lot more.
National Speed
As one of the fastest-growing performance shops on the east coast, National Speed's goal is to improve the power, performance, and reliability of whatever vehicle you are driving. From a Dodge Dart to the Dodge Viper and everything in between, if it's made to go, National Speed can make it go faster. So the next time you're cruising on the coast of the Carolinas, stop by. If it's on a Saturday you'll likely score a free burger from the National Speed grill!