Ordered my timing chain(Cloyes 3072) and Fel pro cover gasket set today, and I think I am finally ready to get the plenum done and ALL of the other things it needs at one time.

So far I have:
Accel plug wires and Champion plugs(on truck already, about 2 weeks old)
Hughes plate kit with new intake bolts and gaskets
Accel cap and rotor
Bosch O2(I know, will get a ntk soon after the repair)
Magnaflow 23285 cat
new purge valve
T/B, EGR, coolant outlet gaskets

I may pick up new upper and lower rad hoses too when I get coolant.

W/P, bypass hose and little outlet(I forget the name lol) are about 2 yrs old, so I plan to just re-use them. I have an impact gun for the crank, but may do the starter method if I feel the rest of the repair is going quick enough/gun wont work, will only have 3 days max time. I am a good with a wrench, but a little slow always trying to do things perfect.. and there will be alot of cleanup.. and beer


I did some searching on this, but didnt find much..

My concern is, when I put the new cat on whats the best way to go about it, my real worry is where the cat piping will meet the old muffler(I can get a pipe cutter, chain type, at my work, I do not have an angle grinder or anything like that yet).

Will I be able to re-use the old muffler and tailpipe with a new clamp? Or should I buy a new muffler too? Never done any exhaust work really aside from bolt on type stuff that didnt need cutting.

Thanks for any advice.

edit: sorry, meant for this to be in other section.

 

Just for now, sleeve, and clamp it. Unless you have access to a welder? If you do, then just weld it back together.

 

Magnaflow will be 2.5" coming out, is this the same as the stock pipe/muffler inlet?

 

Check in the faq section, there is a thread there that details exhaust layout, including pipe sizes.

 

i replaced everything. there's a detailed list at the end of this thread.
do you have, or are you renting a puller for the harmonic balancer?
do you have access to an air gun to remove the crank bolt, or have you got a gadget to hold the engine from turning.

label all your wires and hoses and bolts
https://dodgeforum.com/forum/2nd-gen...ater-pump.html

 

yes our trucks have a 2 1/2 ID pipe.....i just did the muffler on my buddies 92 5.2...did it with a hand saw, took about 1/2 hour total


for the plenum job, might i suggest you take your manifold and bring it to a machine shop to have cleaned...or do what i did, bought a used one and brought it to the cleaner, so i had everything ready to change....but heres the difference, and it only cost $40



BEFORE:









AFTER:








The job is very easy, dont let it overwhelm you, ive done everything your doing....timing chain is easy, you dont need to do TDC....just bfore you take the old one out make sure the Punchmark on the top gear is at 6 o clock, and the bottom is at 12 o clock, thats what i did and never had a problem. and i made sure that the silver link lines up with the punchmark on the top gear when its at 12 o clock







any questions ask, cuz most of us can do that job with our eyes closed....its very simple

 

Ive seen that post before when searching dhvaughan, it was a big help, especially with the pics, and is part of the reason I decided I could/should do the timing chain at the same time as the plenum.

I have an electric impact that should be good to 200ft lbs, I will have an extra set of hands for two days to help with the repair. Hopefully the impact gun with get the balancer off and I wont need need to pull the starter, but I have read about it and I think I am prepared.

Thanks to your post I purchased a 1 1/4 socket for the impact gun beforehand.

I work at a major auto parts chain store(we arent supposed to mention it online) and will be able to rent the harmonic balancer puller from there.



Since it seems to be the same size I may put the cat on and then drive to a local muffler shop to have it welded up, can get the sleeve and clamps at my work as an alternative. I might also buy a Magnaflow 22" or 24" muffler and then just have it all welded up at a shop.

Having the manifold cleaned is a good idea, had planned to just clean it up myself, but your pics show the difference a dip would make, I dont have a solvent tank or anything so I may have it dipped, thank you for posting those pics.

Right now I know I am lacking the one clamp for the cat that doesnt come with the 23285, and need to rent the balancer puller and then should be pretty much ready to do the job. Going to take 3-4 days off for it.