American Expedition Vehicles JK Hemi Builder Kit - Installation Guide for 07-11 JK Wrangler - Manual (Page 5)

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Once the body is separated, it is easy to remove the stock powertrain, weld in the new mounts
and to install the assembled 5.7, 6.1L, or 6.4L powertrain and exhaust into the chassis. While
the body is on the hoist, the completed cooling module, and steering modifications can be com-
pleted. The body is then mated back to the chassis using the reverse procedure, the harnesses
are plugged in, the brake lines are hooked back up and bled, the radiator hoses can then be
connected and the vehicle can be filled with fluid and started.
TIP 2:
There are several variations of sensors, alternators, water pumps, crank pulleys, and power
steering pumps used in different applications from 2005 onward. Please check that you have all
the correct parts listed in the Bill of Materials provided on our website. Using the wrong part can
cause serious damage to other components.
TIP 3:
The exhaust system is designed to fit the 5.7L motor in a stock application. 6.1L and 6.4L mo-
tors use the 5.7 exhaust but will be required to use the 5.7L Manifolds, Gaskets, and bolts also
listed in the Bill of Materials. The routing has been fitted assuming a stock suspension and bum-
pers. The use of aftermarket suspensions, bumpers or other components may require modifica-
tions to the exhaust system or other components. Two Door Wranglers will need a section of tail
pipe cut out of the system.
TIP 4:
Jeep Wranglers being converted from Manual to Automatic Transmissions will require AEV Part
#31001027AA which is an additional wire for the body side of the harness. The other parts re-
quired to perform the manual to automatic conversion are listed in the Bill of Materials.
TIP 5:
Four door wranglers can use the stock driveshaft’s front and rear; two door models will need a
new or modified rear driveshaft.
TIP 6:
WK and XK powertrains come with a rear sump aluminum oil pan (plastic pan on 2011s must be
changed.) This pan will work but is easily damaged off-road. As an option, a steel pan is avail-
able from the Dodge Ram and all parts are listed in the supplied Bill of Materials. LX powertrains
come with a front sump aluminum pan and will need to be changed to the steel pan. Be sure to
reference a 5.7 manual regarding the “Torque To Yield” main bearing cap bolt and always use a
new bolt.