I've got a 5.9 in my '94 Dakota and I've read that with a 5.9 you can take the runners down to the bottom so that's that I'm doing. This isn't a walk through, that's been done. I'm just providing pictures of my mod. I've got the Hughes plenum fix I'm going to be adding to this. I think I'm going to get it ceramic coated since Jet Hot is local. I'll add pictures as I go. I'm just starting out so if it looks rough, I'm far from done.

The tools I'm using:


About what I'm taking off:


Chop:








What a mess:


A.J.

 

That looks pretty awesome!
I'm looking forward to hearing if you notice any difference with the kegger mod done to your truck! I'd really like to do it also.

 

Are you planning on cutting out the center divider? Just wondering because all the ones ive seen modded had the center divider removed.

 

No because the EGR tube is incorporated in it. If I didn't have an EGR than I'd remove it.

A.J.

 

I finished up my kegger mod today. I'm hoping to get it installed this week with the ceramic coated Hughes plenum cover.





I also cleaned up the throttle body bores.



A.J.

 

AWESOME job Man!

 

done mine as well...finally! can't u just block the egr port? thought about a m1 instead but can't justify the price and from the dyno charts I have seen, seems to be more beneficial if u rev the truck alot, I rarely go past 3000 rpms

 

I need the EGR to pass emissions. I tried to get through with the non-EGR intake that came with my engine (it's a '98 5.9) but I failed NOX. At the time I was running the 5.9 with a 5.2 computer with stock '94 fuel pressure. Since then I've upped the fuel pressure and the truck runs better so I might pass but I don't want to take that chance. Besides your engine runs cooler and you get better gas mileage with the EGR working properly.

A.J.

 

Awesome job man! Keep us posted on the difference in power.

 

Got some more pictures.







Hughes plenum cover.


Hughes plenum cover the ceramic coated side.


Through the throttle body, kegger mod.


Through the throttle body, Stock intake. Look how close the intake runner comes to the plenum cover.


Last week I took my truck to the track. I had a problem with detonation because it was 100 degrees and I was running regular gas. Half way down the track it felt like I wasn't getting any faster. I was running a Corvette and I'd get him off the line but by half track he gained on me and passed me, usually only beating me by .1 to .2 of a second. With my kegger mod done, on the road test today, acceleration was smooth and constant. On the on ramp to the highway, it pulled hard and constant all the way up to 90 mph were I let off. I think the combination of the 52 mm throttle body https://dodgeforum.com/forum/1st-gen...ttle-body.html and the kegger mod are the way to go. I would do one without the other.

I'm going to try and make it to the track again this weekend. I'm going to run premium (91 octane the best I can get in AZ without buying race gas) and I also have a '94 5.9 computer I can try and I'll also bring tools and a fuel pressure gauge to play with the 5.2 PCM vs the 5.9 PCM and play with my fuel pressure to stave off detonation.

A.J.