Engine build questions (2004 5.7L)

BushViper5.7 · Jun 19, 2024

Hey y’all! I’m an apprentice machinist and have access to all the bells and whistles in the shop so finally decided to build a solid 5.7 to replace my stock one in the truck right now (2004).

The Holley EFI Gen III Hemi Hi-Ram Intake Manifolds 300-658 on Summit’s website is the intake that I’m planning on running but the application page specifies it’s only for the Eagle series (09+) and I’m curious if I’ll actually run into issues with that, or what those issues may be.

as it sits I have good 5.7 heads I’m going to deck, port and do a valve job on, a shortblock/crank from an 07 300c that I think I’m going to bore out and fit the 6.1 darton sleeves in and will be working with the boss man to figure out what I’m doing internals-wise. Probably wiseco pistons and callies rods. Plan on running compound turbskis @ sub 20 psi and a streetable cam, looking to push past 600rwhp but was wondering if I really need to find a 6.1 crank or if I’ll be fine with the one I have. Just gonna build to the best of my ability and see what actually hits on the dyno whether that be more or less.

I’m dropping a fair amount of money on this build but I also know for a fact I’m overlooking aspects of it and am hoping to figure out those shortcomings before I start working the build sheet.

Reliable and high hp aren’t exactly terms that like to be used together but that’s my goal with it. I’d like to build once, cry once, and be happy with it for the majority of its lifetime. The truck is primarily going to be street and offroad and maybe the occasionally track day for shits and giggles so mostly just some spirited runs and light abuse. With that said I’m all ears for any recommendations in terms of bulletproofing.

lastly, I have a diablosport trinity ex, but know nothing about tuning, not sure if it’s gonna be possible but I’d like the end result to play nice with the pcm and instrument cluster etc.

Thanks in advance y’all!

HemiLonestar · Jun 20, 2024

Ambitious.

BushViper5.7 said:
The Holley EFI Gen III Hemi Hi-Ram Intake Manifolds 300-658 on Summit’s website is the intake that I’m planning on running but the application page specifies it’s only for the Eagle series (09+) and I’m curious if I’ll actually run into issues with that, or what those issues may be.

Port mismatch on pre-eagle heads. I can't remember if there is enough metal to hog out ports that much. If you use eagle or 6.1 heads it won't be a problem (and they already have those ports and larger valves).

BushViper5.7 said:
as it sits I have good 5.7 heads I’m going to deck, port and do a valve job on, a shortblock/crank from an 07 300c that I think I’m going to bore out and fit the 6.1 darton sleeves in and will be working with the boss man to figure out what I’m doing internals-wise. Probably wiseco pistons and callies rods. Plan on running compound turbskis @ sub 20 psi and a streetable cam, looking to push past 600rwhp but was wondering if I really need to find a 6.1 crank or if I’ll be fine with the one I have. Just gonna build to the best of my ability and see what actually hits on the dyno whether that be more or less.

If you intend to keep stock displacement with that much boost (sub 20 is a wide range), yes you'll want a forged crank.

BushViper5.7 said:
Reliable and high hp aren’t exactly terms that like to be used together but that’s my goal with it. I’d like to build once, cry once, and be happy with it for the majority of its lifetime. The truck is primarily going to be street and offroad and maybe the occasionally track day for shits and giggles so mostly just some spirited runs and light abuse. With that said I’m all ears for any recommendations in terms of bulletproofing.
lastly, I have a diablosport trinity ex, but know nothing about tuning, not sure if it’s gonna be possible but I’d like the end result to play nice with the pcm and instrument cluster etc.

So the two major things I was initially looking for was what trans you intend to use (because your stock RFE will tell you to get f*cked in short order with just a moderate power increase) and how you intend to control it (stock PCM ain't gonna cut it).
The stock differentials (you said offroad, so I'm assuming 4x4 since only an idiot takes a 600hp 2wd offroad) will probably hold for a while; t-case will likely be the next weak link after the trans.

BushViper5.7 · Jun 20, 2024

I’ll probably start looking into Eagle heads then or trying to find a different manifold.

As far as displacement goes I’m undecided currently, but the general idea is to bore it out as much as it makes sense to and possibly go the stroker route but 20psi would be the upper limit, however I don’t intend to send more than 12-15 through it for the most part.

I do have the stock RFE behind it currently but I know it ain’t gonna like the power so that’s 100% going to be the next piece of the puzzle and I have a core to build from while I’m driving it as is. I’m still in the planning stage and just trying to work out kinks with the engine currently. I’m running 38’s on the stock diff and I’m about to bite the bullet on a set of 4.56 gears for the diffs.

But yeah, I have the diablosport, but wasn’t sure if I’d need to go further than that. Anywho, I appreciate the feedback on it all!

arocketman · Jun 20, 2024

You're gonna love the 4:56 gears. Welcome to the site.

HemiLonestar · Jun 20, 2024

BushViper5.7 said:
I’ll probably start looking into Eagle heads then or trying to find a different manifold.

If you switch to those heads (fairly cheap) then that manifold will work for you.

BushViper5.7 said:
As far as displacement goes I’m undecided currently, but the general idea is to bore it out as much as it makes sense to and possibly go the stroker route but 20psi would be the upper limit, however I don’t intend to send more than 12-15 through it for the most part.

There isn't much in the earlier blocks for boring, which is why they usually get stroked with a small clean up bore. The 5.7 isn't a performance built block, better off starting with a 6.1 block (reinforced block, piston oil squirters, larger bore).

BushViper5.7 said:
I do have the stock RFE behind it currently but I know it ain’t gonna like the power so that’s 100% going to be the next piece of the puzzle and I have a core to build from while I’m driving it as is. I’m still in the planning stage and just trying to work out kinks with the engine currently. I’m running 38’s on the stock diff and I’m about to bite the bullet on a set of 4.56 gears for the diffs.

A built RFE won't cut it either. No one has been able to build a long term bulletproof reliable RFE for these trucks. You're gonna need a different trans if you actually want to be able to drive it. Either look older (518/46RH or 46RE) or newer (8HP70) Mopar wise; some have used the GM 4L80E. TCI has an aftermarket 6 speed based on the 4L80E.

BushViper5.7 · Jun 20, 2024

HemiLonestar said:
If you switch to those heads (fairly cheap) then that manifold will work for you.

There isn't much in the earlier blocks for boring, which is why they usually get stroked with a small clean up bore. The 5.7 isn't a performance built block, better off starting with a 6.1 block (reinforced block, piston oil squirters, larger bore).

A built RFE won't cut it either. No one has been able to build a long term bulletproof reliable RFE for these trucks. You're gonna need a different trans if you actually want to be able to drive it. Either look older (518/46RH or 46RE) or newer (8HP70) Mopar wise; some have used the GM 4L80E. TCI has an aftermarket 6 speed based on the 4L80E.

If that’s the case I might end up going through with a manual swap and looking into whatever the firepunk guys are doing.

reason I’m sticking to the 5.7 block though is because I got one for $50 and my truck is already full bolt-on so I won’t have to worry about accessories and everything else fitting up.

SUPER BEE · Jun 23, 2024

BushViper5.7 said:
If that’s the case I might end up going through with a manual swap and looking into whatever the firepunk guys are doing.

reason I’m sticking to the 5.7 block though is because I got one for $50 and my truck is already full bolt-on so I won’t have to worry about accessories and everything else fitting up.

Mrs.Studmuffin · Jun 25, 2024

Welcome to our Hemi Family!!

Harleyc04 · Jul 12, 2024

BushViper5.7 said:
If that’s the case I might end up going through with a manual swap and looking into whatever the firepunk guys are doing.

reason I’m sticking to the 5.7 block though is because I got one for $50 and my truck is already full bolt-on so I won’t have to worry about accessories and everything else fitting up.

your timing cover and accessories will bolt up to the 6.1 block

3dodgechick · Aug 7, 2024

BushViper5.7 said:
Hey y’all! I’m an apprentice machinist and have access to all the bells and whistles in the shop so finally decided to build a solid 5.7 to replace my stock one in the truck right now (2004).

The Holley EFI Gen III Hemi Hi-Ram Intake Manifolds 300-658 on Summit’s website is the intake that I’m planning on running but the application page specifies it’s only for the Eagle series (09+) and I’m curious if I’ll actually run into issues with that, or what those issues may be.

as it sits I have good 5.7 heads I’m going to deck, port and do a valve job on, a shortblock/crank from an 07 300c that I think I’m going to bore out and fit the 6.1 darton sleeves in and will be working with the boss man to figure out what I’m doing internals-wise. Probably wiseco pistons and callies rods. Plan on running compound turbskis @ sub 20 psi and a streetable cam, looking to push past 600rwhp but was wondering if I really need to find a 6.1 crank or if I’ll be fine with the one I have. Just gonna build to the best of my ability and see what actually hits on the dyno whether that be more or less.

I’m dropping a fair amount of money on this build but I also know for a fact I’m overlooking aspects of it and am hoping to figure out those shortcomings before I start working the build sheet.

Reliable and high hp aren’t exactly terms that like to be used together but that’s my goal with it. I’d like to build once, cry once, and be happy with it for the majority of its lifetime. The truck is primarily going to be street and offroad and maybe the occasionally track day for shits and giggles so mostly just some spirited runs and light abuse. With that said I’m all ears for any recommendations in terms of bulletproofing.

lastly, I have a diablosport trinity ex, but know nothing about tuning, not sure if it’s gonna be possible but I’d like the end result to play nice with the pcm and instrument cluster etc.

Thanks in advance y’all!

Holley single plan Intake, for the 03-08 heads, you have two options,
1) weld up the ports and reshape them to match the older heads, Con= you lose about 30Ft lbs of Tq under 3200rpms, need an elbow or need to have a 4BBl to Mopar TB adaptor plate made, I think OCPerformance is still making them.
PRO...not much, it'll pull like a freight train all they up to 7k and with the right tune , it'll still make useable power all the way up to the oil pump cavitates.
2) buy the Holley adaptors to go from Eagle/6.1/6.4 port to 03-08...Con: price , still have the lack of Tq under 3k problem, not as bad, the Adaptors add 3/4 inch to the runner length, which gets you close the the runner length in the stock truck intake, the big issue with the Holley single plan intake is the approach to the port opening in the 1st place...Air is HEAVY and AIR does not like to change Directions.

545 trans................Junk 450-500hp is where they start to say ......Screw you I'm out of here, the later PCMs are easier to program , and you can use some tricks to help, 08, 10-14 we can just about tune out the Prime gear to keep it from hitting to hard, but it's not a cure, you can get it the RFE65 in the 13's and 14s to get close to 550-600 but it's still a time bomb waiting to leave you stranded....... the 545/65 trans is crap.....Nag,HP80 46RH , T-56( my favorite) are your best options, Cheapest would be a 46RH(A518) bolt in, uses stock drive shaft(4x4..Not so much) For the All out take no prisoners the Old school 727 is hard to beat...but you give up OD .

Darton Sleaves , Take a F'ton of machining to make work in the open deck 5.7s,(been there done that, nothing like 458Ci and 5.7 still casted to the side of the block....4.165boreX4.20stroke), LS sleeves can be mad to work....4.22bore max.
The limitation of only 8 functioning head bolts , you always have sealing issues especially with any boost level over 14lbs, Copper gaskets can help but, its only a band aid(Clark Copper Head gaskets....ONLY!!!!!!!!!!!!!!!!!!! No others will work PERIOD .)

The 5.7 Cast crank will take up to 1000hp as long as the tuner is good, my uncle as a customer who has been running a 347Ci 5.7 with the oem crank up in to the low 800s for 6 years and 90K miles ....There's a guy who runs a Wagoner with a 5.7 eagle compound turbo set up who has been in the low 900Hp on the stock 5.7 crank....BUT best option is the Hellcat crank, you will need to trim the nose of the crank, but there are stock Hell kitty cranks hitting 1200hp, again if the tune is correct.

Dump Diablo , Go HPtuners

03-08 5.7 blocks can and have been bored out to 4.00 and 4.03 since 2008 , Nutter racing in Washington state were doing it 08, taking 6.1 pistons and boring the 03-08 blocks out to 4.055, I think that's too much self, My uncle has a 444 CI 5.7(4.08X4.25) that he built in 2017 , it had about 35k miles on it before it was pulled out for a Hellcat crate engine swap....Bores on the trip4 look good yet, only .005 runout , which for a stocker is high but for stroker like that , it's good.

SUPER BEE · Aug 7, 2024

3dodgechick said:
Holley single plan Intake, for the 03-08 heads, you have two options,
1) weld up the ports and reshape them to match the older heads, Con= you lose about 30Ft lbs of Tq under 3200rpms, need an elbow or need to have a 4BBl to Mopar TB adaptor plate made, I think OCPerformance is still making them.
PRO...not much, it'll pull like a freight train all they up to 7k and with the right tune , it'll still make useable power all the way up to the oil pump cavitates.
2) buy the Holley adaptors to go from Eagle/6.1/6.4 port to 03-08...Con: price , still have the lack of Tq under 3k problem, not as bad, the Adaptors add 3/4 inch to the runner length, which gets you close the the runner length in the stock truck intake, the big issue with the Holley single plan intake is the approach to the port opening in the 1st place...Air is HEAVY and AIR does not like to change Directions.

545 trans................Junk 450-500hp is where they start to say ......Screw you I'm out of here, the later PCMs are easier to program , and you can use some tricks to help, 08, 10-14 we can just about tune out the Prime gear to keep it from hitting to hard, but it's not a cure, you can get it the RFE65 in the 13's and 14s to get close to 550-600 but it's still a time bomb waiting to leave you stranded....... the 545/65 trans is crap.....Nag,HP80 46RH , T-56( my favorite) are your best options, Cheapest would be a 46RH(A518) bolt in, uses stock drive shaft(4x4..Not so much) For the All out take no prisoners the Old school 727 is hard to beat...but you give up OD .

Darton Sleaves , Take a F'ton of machining to make work in the open deck 5.7s,(been there done that, nothing like 458Ci and 5.7 still casted to the side of the block....4.165boreX4.20stroke), LS sleeves can be mad to work....4.22bore max.
The limitation of only 8 functioning head bolts , you always have sealing issues especially with any boost level over 14lbs, Copper gaskets can help but, its only a band aid(Clark Copper Head gaskets....ONLY!!!!!!!!!!!!!!!!!!! No others will work PERIOD .)

The 5.7 Cast crank will take up to 1000hp as long as the tuner is good, my uncle as a customer who has been running a 347Ci 5.7 with the oem crank up in to the low 800s for 6 years and 90K miles ....There's a guy who runs a Wagoner with a 5.7 eagle compound turbo set up who has been in the low 900Hp on the stock 5.7 crank....BUT best option is the Hellcat crank, you will need to trim the nose of the crank, but there are stock Hell kitty cranks hitting 1200hp, again if the tune is correct.

Dump Diablo , Go HPtuners

03-08 5.7 blocks can and have been bored out to 4.00 and 4.03 since 2008 , Nutter racing in Washington state were doing it 08, taking 6.1 pistons and boring the 03-08 blocks out to 4.055, I think that's too much self, My uncle has a 444 CI 5.7(4.08X4.25) that he built in 2017 , it had about 35k miles on it before it was pulled out for a Hellcat crate engine swap....Bores on the trip4 look good yet, only .005 runout , which for a stocker is high but for stroker like that , it's good.

Mrs.Studmuffin · Aug 8, 2024

3dodgechick said:
Holley single plan Intake, for the 03-08 heads, you have two options,
1) weld up the ports and reshape them to match the older heads, Con= you lose about 30Ft lbs of Tq under 3200rpms, need an elbow or need to have a 4BBl to Mopar TB adaptor plate made, I think OCPerformance is still making them.
PRO...not much, it'll pull like a freight train all they up to 7k and with the right tune , it'll still make useable power all the way up to the oil pump cavitates.
2) buy the Holley adaptors to go from Eagle/6.1/6.4 port to 03-08...Con: price , still have the lack of Tq under 3k problem, not as bad, the Adaptors add 3/4 inch to the runner length, which gets you close the the runner length in the stock truck intake, the big issue with the Holley single plan intake is the approach to the port opening in the 1st place...Air is HEAVY and AIR does not like to change Directions.

545 trans................Junk 450-500hp is where they start to say ......Screw you I'm out of here, the later PCMs are easier to program , and you can use some tricks to help, 08, 10-14 we can just about tune out the Prime gear to keep it from hitting to hard, but it's not a cure, you can get it the RFE65 in the 13's and 14s to get close to 550-600 but it's still a time bomb waiting to leave you stranded....... the 545/65 trans is crap.....Nag,HP80 46RH , T-56( my favorite) are your best options, Cheapest would be a 46RH(A518) bolt in, uses stock drive shaft(4x4..Not so much) For the All out take no prisoners the Old school 727 is hard to beat...but you give up OD .

Darton Sleaves , Take a F'ton of machining to make work in the open deck 5.7s,(been there done that, nothing like 458Ci and 5.7 still casted to the side of the block....4.165boreX4.20stroke), LS sleeves can be mad to work....4.22bore max.
The limitation of only 8 functioning head bolts , you always have sealing issues especially with any boost level over 14lbs, Copper gaskets can help but, its only a band aid(Clark Copper Head gaskets....ONLY!!!!!!!!!!!!!!!!!!! No others will work PERIOD .)

The 5.7 Cast crank will take up to 1000hp as long as the tuner is good, my uncle as a customer who has been running a 347Ci 5.7 with the oem crank up in to the low 800s for 6 years and 90K miles ....There's a guy who runs a Wagoner with a 5.7 eagle compound turbo set up who has been in the low 900Hp on the stock 5.7 crank....BUT best option is the Hellcat crank, you will need to trim the nose of the crank, but there are stock Hell kitty cranks hitting 1200hp, again if the tune is correct.

Dump Diablo , Go HPtuners

03-08 5.7 blocks can and have been bored out to 4.00 and 4.03 since 2008 , Nutter racing in Washington state were doing it 08, taking 6.1 pistons and boring the 03-08 blocks out to 4.055, I think that's too much self, My uncle has a 444 CI 5.7(4.08X4.25) that he built in 2017 , it had about 35k miles on it before it was pulled out for a Hellcat crate engine swap....Bores on the trip4 look good yet, only .005 runout , which for a stocker is high but for stroker like that , it's good.

Welcome to our Hemi Family!!

Engine build questions (2004 5.7L)

BushViper5.7

HemiLonestar

BushViper5.7

arocketman

HemiLonestar

BushViper5.7

SUPER BEE

Mrs.Studmuffin

Harleyc04

3dodgechick

SUPER BEE

Mrs.Studmuffin

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