2001 Dodge Ram 1500 - Intake Manifold and Plenum Gasket Repair - Part 4
ฝัง
- เผยแพร่เมื่อ 5 ก.ค. 2014
- In this video series, I show the steps required to replace the plenum and intake manifold gaskets in my 2001 Dodge Ram 1500 4WD with the 5.9L Magnum engine. Included in the repair is the installation of a new 1/4" aluminum plenum plate from Hughes Engines. This kit is available at:
www.hughesengines.com/Index/pr...
Part 1 - • 2001 Dodge Ram 1500 - ...
Part 2 - • 2001 Dodge Ram 1500 - ...
Part 3 - • 2001 Dodge Ram 1500 - ...
Part 4 - • 2001 Dodge Ram 1500 - ...
Part 5 - • 2001 Dodge Ram 1500 - ...
Part 6 - • 2001 Dodge Ram 1500 - ...
I am not a professional mechanic, and my videos are not intended to offer professional advice. Always reference your vehicle's service manual for official information, and please do not attempt any repair that you are not comfortable doing.
Thanks for watching! - ยานยนต์และพาหนะ
Thanks for taking the time to explain this. And for the few idiots that down voted this please get a friggin life. Once again, thanks for all your time and effort. I've saved a ton of money by watching TH-cam and learning how to repair a car, mower, washer, dryer, fridge and anything else. Thanks Matt!
You're very welcome! I'm like you - I have been helped countless times by other people that have taken the time to post a how-to on TH-cam, so this is kind of my way of "paying it forward." It makes me feel good every time someone tells me that there were aided by one of my videos. So thanks for taking the time to post your message!
And I don't sweat the down votes - you can't please everybody. I do have to chuckle sometimes about the people that go out of their way to nitpick a free video that attempts to help people save money, but hey...we all get our kicks in different ways :-)
I like to use the green scrub pads for washing pots and pans, they scrub the gasket areas clean pretty good without damaging anything. And you can get like a 3 pack from dollar store.
Thanks for taking the time to make your videos it is appreciated
Vince Zellmer No problem, Vince! I'm glad you found them helpful. Thanks for watching!
4 years later, still very useful, thank you.
^^same
Thanks man. Just used your video to get my truck fix. Awesome stuff!
Just did this repair on my 98. Managed it in two nights and without removing fan or shroud. She went from a two pack a day cough to purring like a kitten. Great videos, extremely helpful!!!!
Thread locker and Black RTV, excellent call!
That is awesome! Great work! I'm so glad to hear you found this helpful...congratulations on making the repair on your own!
Thanks for watching!
Great helpful video, great work. And yes, always buy new intake manifold gaskets as well rather than re-use older and redo black rtv for corner mating points.
Painters tape over the throttle body holes keeps objects from falling in.
Great video Matt thanks. I’ll be doing this job soon on mine as well.
Your vids have been a big help. Thanks a lot.
That is great to hear! Thanks very much for watching!
Clinical ...great video thank you.
Getting ready to do this myself, truck suddenly started using lots of oil, hoping this is what it is, thanks for the video
im doing mine too, im not using tread lock my bolts have lock washers but i did use black rtv all around the gasket both sides . and going the picker sensor disb. cap and rotor wires spark wires and valve cover gasket with a touch of blue and red paint new o ring injectors and flushed and cleaned all injectors and modded the kegger a little and TB going with an electric fan mod and getting new belt with idle and tensioner pullies
Muchísimas gracias 👍
The Haynes Manuel says to use rtv on the plenum pan as well. That might've been my problem
I have a 2000 5.9 dodge mag an I discovered the failure when I took the throttle body off to clean it up. Noticed the oil inside and have taken everything apart thanks to you're lovely videos but I noticed there is a ton of carbon build up. Any suggestions for this ?
THANK YOU
I'm going to be doing this same job on my 2001 .. not looking forward to it. I will be doing this job carefully as I can. I don't want to do it twice. Great video.
Hi Matt, just wanted to know how its holding up this time. Any leaks? I’m thinking of doing this job to my 2001 ram.
Hey Matt next time get you some fine grit sand paper on your electric sander or on your dremel tool and it will clean the old gasket off those heads. You can also use a wire brush on a drill. They will shine like new! Good work friend.
Aluminum will be damaged never use any wire brush to clean any gasket surface , a green scotch bright will ruin marine surfaces .... no sandpaper ever
@@nadronnocojr I believe the heads are cast iron.
cool, you don't have to take the distributor off. I'm just feeling to lazy to mess with it after having to deal with everything in the way of the intake lol. That and my oil sensor is a copper hard line so I'd hate to remove that, but appears both can stay in place for this.
Stud were a great idea. Gonna do that. Thanks for your help.
We purchased a gasket kit from Advance, the front and rear crossover gaskets do not have those plastic/metal dowels to line up to the holes, should we be worried using those?
What size bolts are they for the intake?
Holly cow. What a job. Hat off to you sir. I'm not that brave.
Thanks
I always use red gasket sealer on the plenum gasket... glue it in place !!! Clean it really good, gasket sealer on both sides of gasket, replace and tighten down by finger and snug just a bit, let sit overnight, torque the next day... never had another blow out.
Yes I agree, I use ultra grey and partially tourque them, come along the next day after the sealant has set up and complete tourquing
How would you recommend to clean the injector ports, I decided to spray paint my manifold since I have it out and cleaned up, and some of the paint got into the injector ports - I plan to use orange locktite on those plenum bolts and am also going to apply ultra grey to both sides of that gasket. How frustrating that you have to do that again so soon, it is quite a chore for sure
That's fine. Lol. Good video also!
I never used the 3 step sequence and never torqued them never had no problems just choke up on a 1/4 inch ratchet tighten with one hand. Work from center out.
Matt, not to nick pick but the tightening sequence for the first 4 bolts is in 12 in. lbs increments per bolt. So the correct sequence for bolts 1-4 is 12 in lbs per step so 12 then 24 36 48 60 72 in. lbs. then you move on to Step 2.
That "could be the problem" for him the first go around?......just sayin
I bought a 6061 T6 aluminum plenum plate off eBay and the plenum bolts , lock washers , and flat washers for 65 bucks excellent quality, it has worked awesome for 70k miles so far . The seller was Mitch42581 he sells other miscellaneous items as well .
Did it stay sealed?
Is there anywhere I can get a pdf of this manual you have
Did u use the regular gaskets. Or the upgraded fel-pro ones?
I had the same failure at the same location on the plenum plate you did approx 8 months are doing the job the first time. I used blue thread locker and the bolts weren’t loose. Have you had the issue come back up?
When I filmed this video series, it was the second time I had made the repair in about 12 months. The first time, I replaced the stock plenum plate with a new aluminum plate from Hughes Engines. The bolts that came with the kit already had threadlocker applied, so I didn't use any additional threadlocker. Unfortunately, after about a year, some of them loosened up and the gasket failed again. The second time I made the repair, I made sure to use additional threadlocker. As far as I can tell, the gasket is still holding today, about 4 years later.
Sorry to hear that your first repair failed like mine did. Great work on tackling this yourself though!
Thanks for watching!
what would be wrong with sanding both surfaces then putting the plate on with NO GASKET and putting JB Weld in there?? We want it to be permanent right? Just asking....
I'm in the middle of this repair on my truck. I had great success removing old gasket material with oven cleaner. I sprayed it o and let it sit over night. The next day, it peeled off like hot butter with a razor blade.
Dont they make a high-pressure gasket with brass orings and a wire squeeze gasket ?
7 years down the line..Have you replaced the gasket since?
I've read alot about this issue. Is it the length of the plenum plate bolts or the difference in the two metals that is causing the plenum gasket to blow?
Neither, it is a piss poor design
Any link to the Hughes repair? Does it come with all the gaskets?
Nevermind I see you linked us below. Does the plate come with all of the gaskets you need?
That plenum plate was from ?(hughs)?? I need a link of any info on that you can give. I can't believe you fit in there!!! I'm fat!! I still haven't figured out how to get in there without just yanking the front end off!!! LOL. I'm gonna be doing it twice because I fiqured "Betzy" deserved some maintience and was gonna change the thermostat and broke the left bolt off...the drill slid off center... Total mess! I gotta replace the keg at some point ... So I fiqured I'd get everything ready and do the better fuel injectors too. I'm at 175k so the timing chain is due also ...!! New heavy duty Trans has her rockin though!!! Great video... Lots of info and very clear discription !!! A+++, dude!
Haha, wow it sounds like you have quite the project going on! Good luck with all of it, and thanks for the kind words! As for the Hughes plenum repair kit, check out the link below. I hope this is helpful. Let me know if you have any other questions...I'll try to help as best I can.
www.hughesengines.com/Index/products.php?partid=27091
I have an idea! I used blue threader locker but I didn't let anything sit and harden up. Do you think that could've been my problem? bolted everything back up and ran it
Richard Cowtails That might be part of the problem. I think I let my intake sit for several days before I had time to re-assemble everything and actually run the truck. I don't remember what the threadlocker packaging says, but I imagine it tells you to let the product cure for 24 hours or so.
Have you already started the repair again?
I haven't started it yet. I'm still waiting for my gaskets kit from hughes.Was thinking about videoing some stuff on the repair. You have got a great video(s) or maybe just my take on it. If you need anyhting from the mauel haynes, I got one.I can help you in any way. just hit me up
The instructions say to apply a small layer of black permatex sealant on both sides of the gasket. I am about to do mine, just wondering if that's necessary or not.
Yes, you should do that
Bought an SST Magnum 5.9 it doesn't idle too rough but I want get I back to 100 suspect the plenum was it worth it? I got it cheap and it had a k&n installed and a few vacuum tubes flapping in the wind it obviously needs some work no trans or power steering cooler trans is looped.
Any link to the service manual you use.
Thanks for that link! I'm losing the keg for the edelbrock intake/rails/and some new injectors!!! Betzy's gonna jump! LOL. Well kinda......
Nice! I actually wish I had done the same....I find that I'm constantly paranoid that my plenum has failed again, haha. If I end up keeping this truck for a long time, I may eventually pull the engine, put on new heads, and get the Edelbrock intake. That's a long way down the road, though. I need my wife to finish nursing school and to get my daughter out of daycare and into public school before I have the funds for that!
Let me know how the swap goes, and how the truck runs when you're done. I bet it's going to be sweet!
That’s crazy that the plenum plate from hughes didn’t fix it. Did u have vacuum in the crankcase?
hello matt, I'm doing this on my 99 dakota, for about 2 weeks now, can I buy just the plate which is 7715 for the part number, is it still as thick
it's on hughesengine also
According to the Hughes website, their kit "Fits All 1992-2003 V8 Magnum (Dodge & Jeep, 5.2L & 5.9L) Engines". So, you should be good, but it may be worth a call to them to confirm.
Thanks for watching! Good luck with your repair.
Where I work we just put stuff together with the rags and towels still in there, no Foreign Material Exclusion training here!! lol
***** Haha...what's the worst that can happen, right? Thanks for watching!
did you use blue thread locker?
Richard Cowtails Richard, sorry for taking a while to respond...things have been a little hectic recently. Yes, I believe the thread locker I used was blue.
How long does it take on average to do the repair? My local Dodge dealer says if i buy the parts they would fix it but said it is a 6 hour job and would cost me 600.00 labor!
Roger, I would estimate this takes between 12 and 16 hours if you've never done it before. A seasoned mechanic should be able to do it in 6 hours, and $100/hour labor is honestly not that bad, at least for where I live. With that said, with a few basic tools and some patience, you should be able to do it yourself if you are motivated to do so. I would give yourself a long weekend just in case, and would recommend you have a helper to hand you tools as needed...I can't even begin to estimate how much time I wasted crawing in and out of the engine bay fetching tools I couldn't reach!
Good luck, and I hope you can get your truck running better soon!
My husband just did this in 10 hours...sadly today next morning he heard a whistling so apparently back to leaking and I'm happy to find your videos and the use of the blue bolt tape may be something he may not have used, not sure. but beyond frustrated with this truck!! Thanks again Matt and trying to find the download you mentioned at the 6 mark of this video to download it.
Did you use the ultra black rtv inthe fron and back fgaskets of the intake? those rubber ones.
Richard Cowtails Richard, the only place I used RTV was in each corner of the block where the intake manifold gaskets meet. I basically put a small bead in the "V" where the sides slope down to meet the flat section of the block. Does that make sense?
yes, ofcourse. im using permatex insensitive thread locker this time. suppose to block oil. Hughes actually sent me a free set of gaskets. super nice of them. Im going to have to talk them up to my friends and family. awesome. I cant imagine why the gasket failed. doesn't make sense. ill be using rtv ultra black on the plenum pan this time. It seems as if fel pro gaksets are better quality then what doorman provides. aka hughes lol
Richard Cowtails That is really cool about Hughes sending you new gaskets. They seem like a good company.
It's a bummer about your second gasket failure. Hopefully the threadlocker and RTV will take care of things this time. You also may want to test your torque wrench to make sure it's calibrated. It's very possible that improperly torqued plenum plate bolts could cause the failure, too.
Good luck!
great ideas, thank you
Hey I did the hughes repair... and my gas mileage has gone to shit after wards. any ideas? i screw up the upper intake? the plenum isn't leaking.
what about metal sand paper? is that good to use to clean?
Richard Cowtails Richard, I'm not sure about that. I suppose you could use some very fine sandpaper like 2000 grit or finer, but you are still going to be making microscopic gouges in the engine block's mating surface. Perhaps someone with better knowledge than me can chime in. Odds are you would probably fine to use very, very fine sandpaper to lightly clean, but I would be extremely cautious in doing so.
I'm done with this damn thing lol. I'm takin it to a shop.
What is the impact on fuel economy, if any, with this particular issue?
i drive a lot and was losing about 2 quarts a day oil is high now days5 bucks a day about 1800 a year, with a vacuum leak it can run lean and have more wear on the engine , but i think on this engine with the drop in vacuum the injection on time is longer and wasting gas
What is an big issue is you start burning oil in the combustion process & thus plugging up your cat
Before sitting the kegger back in you put the black RTV around the corners, but why didn't you apply a bead around the entire perimeter of it before installing it?
+nojunkorspam The instructions that came with the Hughes plenum kit just said to use the RTV in the corners, and that's just because that's where the two FelPro gaskets meet, so there is a "seam" there. I'm not sure about doubling up RTV and the gasket. I guess that might work, too, but I was just following the instructions that came with the kit.
OK cool. Thanks for the video because I have a 360 that needs some work, but thankfully I can skip a lot of your steps because it is sitting in my garage instead of inside a truck :)
+nojunkorspam No problem! That's nice - skipping steps is good! Just take your time, and definitely make sure you clean up the gasket mating surfaces well. Also - be sure to use thread-locker on the plenum plate bolts; I didn't the first time because the new bolts came with some thread-locker already on them, but they failed within 9 months. The second time, I made sure to add thread-locker and the repair seems to have lasted.
Good luck!
Thanks for the video! Question you mentioned that your original bolts came with the thread locker so you you didn't add anymore, you think that is why the plenum gasket failed? Because the screws worked there way loose?
Ribeye Robert D libtard
Aren't the heads iron?
Iron heads, aluminum block and intake, steel plenum
Dodge was on crack when they designed this
Is it still holding up? Im doing this now the gasket maker is was scares me
i am having some issues and trying to figure out my problem... Truck is a 97 dodge ram 1500 2wd 5.2... Truck may start up fine one day but other days truck starts up and dies if i use keep rpms up for a lil bit and then it will idle and be some what fine
John Hammond Hmm, John I'm no expert but it sounds like you could possibly have an issue with the Idle Air Control valve in the throttle body. It opens and closes to adjust the airflow into the intake when the throttle plates are closed (when the truck is idling). If this gets clogged up, it could be restricting airflow at idle and choking the engine out. That might explain why it would run OK if you keep the RPMs up, because then you are allowing air into the intake through the throttle plates. I would start there. I believe I show this cleaning process at about the 5:00 mark of Part 5 of this series. That may not be the only issue you're having - in my limited experience, it seems most issues seem to be the combination of several factors - but it's a simple, cost-free check and a good place to start.
Let me know if you figure it out. Good luck, and thanks for watching!
My truck was doing the same thing. It turned out to be the catalytic converter.
Is it just me but does 12 foot pounds feel loose?
i have the same motor in my 93 dodge Dakota i was told it's a 318 I'm thinking now it might be a 360 how can i tell the difference
Probably the most fool-proof way (if you're fairly certain your engine is original to your truck) is to request your truck's build sheet from Dodge, which you can do via the link below. That will tell you which engine the truck was equipped with from the factory.
www.dodge.com/webselfservice/dodge/emailpage.html?appStr=wccs&titleStr=Contact+Dodge&familyStr=brand&franchise=D&actionURL=%252Fwccs%252Fbrand_forms%252Fus%252Fwebform.jsp&promotion=null&category=U
Thanks for watching!
Driver side of the block behind exhaust manifold Will have it in the casting last 3 digits
On your first attempt repairing the plenum, did you break any of the intake manifold bolts? I broke 3 and was wondering if you had any special way of getting them out?
+Jared Kaufman Hey Jared, I did actually break one manifold bolt off in my first repair. I seem to remember it was near the front of the manifold toward the radiator. I got lucky and it snapped off an inch or so above the surface of the engine block, so I had some "meat" left to grab onto. I think what worked for me was first soaking it with PB Blaster and leaving it overnight, and then using heat and a pair of channel locks to grab onto it. Then I alternated tapping the end of the broken bolt with a hammer and trying to work it loose with the channel locks. Lo and behold, it eventually broke loose and came out in one piece, but it looked pretty hairy for a while.
I would start by doing that. If your bolts are snapped off near the block, then it's going to be a lot more difficult. I'm probably not qualified to give you much advice on that procedure.
Good luck! Let me know what you end up doing.
Ok thank you I appreciate the advice! I will let you know how it goes.
Did the 2001 ram have an egr system? Mine ties into the back of the manifold took me by surprise after watching videos lol very hard to get to I have a 94 had alot of vacum lines as well but videos helped alot in all other aspects thanks for the help
No. 94-95 are EGR and 96 have the EGR tube in the intake but don't use it. Chrysler just reused the old intake. 97+ has nothing to do with EGR.
Nichelle Wheelus Subia Thanks for watching! It looks like you got your answer below. Thanks for the assist, MrBlurberries.
84 inch pounds is way loose !!!! I would go hand right with the blue lock tight , and a grade 8 lock washer ! 2 light coats of spray tack gasket spray IV never had it fail . Good video though .
can anyone please tell me why my 2001 dodge 1500 is leaking oil in to the exaust on passenger side and very back plug was filed please help me oh and truck still runs great but smokes white smoke bad
Bob, sorry to hear you are having some issues with your truck. The oil leaking onto the exhaust manifold is most likely coming from the valve cover gasket. I would start by removing the valve cover and replacing the gasket to see if that solves your problem.
Regarding the oil on the spark plug hole, I can't remember if there are seals for the spark plug tubes in this engine or not. If so, that is probably the culprit.
The white smoke is a little more concerning, as that generally indicates coolant in one or more combustion chambers. Has your engine coolant level been dropping consistently? If so, you might want to do a quick test to see if you have exhaust gases in your coolant, which indicates a head gasket failure between a combustion chamber and a coolant passage. To do this, start with a cool engine, and remove the radiator cap. Then start the engine and allow it to warm up to operating temperature. If you see bubbles rise out of the coolant at the radiator cap opening, then it is a pretty good assumption that you have a head gasket leak. Hopefully that is not what is going on.
I hope this is helpful. Good luck!
You can try re-tightening the valve cover gaskets before replacing (they are meant to be reused). I had both of mine leaking and after torquing them back down to spec leak is gone. 5.9 2001 Durango.
If it's blowing white smoke there's a good chance your head gasket is bad and allowing coolant to enter into the cylinder which causes exhaust to to appear white in color. Eventually it will smear the cylinder and rings on the one it's leaking into. Pull each plug the one that's burning pure white with no corrosion is the leaking cylinder.
Oh , and you do not have to pull the fuel rail off of the intake to do this just simply disconnect at quick connect at fuel rail on drivers side. If you do you should replace the rubber o ring gaskets the the injectors slide back into on the intake. Or they can leak but not always.
what torque wrench did you use?
+Richard Cowtails Hey Richard, I just have a cheap Pittsburgh Tools torque wrench that I bought at Harbor Freight. I don't trust its accuracy all that much, and in hindsight I wish I would have spent a few more dollars to get a quality wrench, although I've never tested it to actually see how accurate it is.
probably get a snap on torque wrench then, huh? If I can ever help you out with anything let me know, man.
+Richard Cowtails You can probably get a perfectly capable torque wrench without paying for a Snap On, but a Snap On would definitely do the trick.
looking at ebay. good prices
I never took it to a shop lmao
did anyone just WELD the alum together?? like - why need a gasket at all? - also I would mod the keg/TB while yer at it. ( I have yet to do myself tho - Im all talk lol) :D great vid thx
Hmmm. Been doing that way for 19 years never had an issue. Can you tell me why I never had a promblem..? I always use steel plenum gaskeks.lol. Mr know it all.
I'm sorry if I came across as a "know-it-all" - I try my very best to portray the fact that I am a novice who is simply trying to help people out. The Dodge Magnum plenum failure is an extremely common problem. I have read differing opinions about the cause; some folks say that it is because of the steel plate vs. aluminum intake manifold, while other folks say it is simply due to a manufacturing defect that caused the plenum bolt holes to be shallower than the shaft of the bolts, meaning that the bolts bottomed out before they reached the required clamping force on the gasket/plate.
Everything I know about the issue was learned by reading DodgeForum.com, namely the following thread:
dodgeforum.com/forum/2nd-gen-ram-tech/286307-end-all-be-all-plenum-thread.html
Take care.
On my Gf account Anyways............. don't apologies to this idiot he's wrong your correct. The metal and aluminum expand at different rates and different amounts and after it dose that thousands of times.... It becomes a problem. Iv had 3 Dakota R/T's that all did this and a Ram all 360's all had this problem everyone will tell you the same thing with any research at all. HELL Chrysler said it was a problem and put out a "Fix" for that exact metal piece for this exact issue. F this d -bag. "YOUR wrong because I said so"..... fuck off wayne your wrong Chrysler says so...... and so do I.
Doorman is probably the best gasket set to buy, huh?
Richard Cowtails Richard, sorry for taking so long to reply....I'm not sure about Dorman gaskets honestly. I've always been partial to FelPro myself, but that's not to say Dorman products are poor quality. Just not familiar with them.
@@mattpayne4087 In your video the Intake gasket was a dorman one
Best bet to put gaskets on.... copper coat, it truley works wonders for this repair.
why you dont show in the video,,how to set the torque ratchet????how some people could know if they are giving the proper adjusting to the bolts????it s dificult for you to do that???
jch67ess 12:20
If you don't know how to use a torque wrench, you probably shouldn't attempt this repair
K Aitch truth
Great video but only way to fix this this for sure is to buy a Ford
Trade this issue for several others ?
Video was helpful but you tend to ramble on a bit. Try working on getting to the point faster.