Originally Posted by BoilerUpXFire
The weakest link is the clutch and flywheel setup, with something more substantial, I think the manual would hold up to at least 400WHP, which is quite a large improvement over stock, roughly 2.5 times actually
I've been working closely with Competition Clutch, met up with their engineer Monday. As soon as I get him a clutch and flywheel he is going to make a new single mass steel flywheel (and yes, it will have a trigger wheel for the stock crank position sensor) as well as a new clutch.
Clutches are rated by torque capacity, not horsepower. He says with a single disc 500ft lbs is very doable so thats the good news.
As far as swapping transmissions with the SRT motor... The SRT uses a different bolt pattern on the rear of the crank compared to the NA cars. This is due to the different flexplate/torque converter.
There are 2 ways to do the swap.
1) Machine a spacer/adapter for the NA flywheel. As a result of this you would need a spacer between motor and bellhousing, as well as a shorter driveshaft and revised shift linkages.
2) The way HDDP did it. He swapped cranks between his NA and SRT motor. The cranks are identical between motors. This requires a lot of work (not for your basic mechanic) as you basically have to pull the bottom end of the motor apart, you need new rod and main bearings. But before you can order new bearings you need to MIC the crank journals on both the rods and mains, in addition to the rods and crank main caps then do some math to figure out what bearing size to run.
You also need the clutch pedal from a M/T car as well as the driveshaft. This requires drilling out the pre-stamped indentations of the firewall and running a clutch line and lines for the master cylinder. You also need the shift linkages and such as well as the interior trim pieces.
The one thing no one knows is how the SRT PCM would like the manual, as the PCM on the SRT's also controls the automatic transmission. Without some clever fooling of the ecu it will probably throw codes. HDDP had an NA car that he swapped the SRT motor into. The difficulty here is you can't just run the NA ecu with reprogramming.
The SRT motors do not use MAF sensors, simply MAP. HDDP ran a standalone so he got around all of the above issues on the electrical side of the car. It took a lot of work to integrate the standalone with the CAN system. This also means the car can no longer be emissioned, as the OBD system is no longer there... and no one makes a standalone with OBD capacity as the programming has yet to be unlocked, nor intergrated into a non-oem ecu.
The cost alone is prohibitive, also unless you are very mechanically inclined and are a decent fabricator theres no way you would ever accomplish this project.