The thin steel plate warps a lot more between the bolts than the aluminum plate does. Dodge used the steel plate because it's cheaper, simple as that. Not to mention the bolts are too long (so you think you are torquing correctly, when in reality the bolts are bottoming out)and are spread too far apart in certain areas of the plate.

 

Ok. Now I'm confused and I don't want to do this twice. Has anyone with the fix (aluminum pan) had a leak after.

 

Get the Hughes or APS along with ALL new bolts(intake and pan) and do it once, or you can spend $600 and get the Hughes F1 intake.

 

So, I finally finished my plenum job.
After all was said and done I ended up replacing/perfoming the following.
FABRICATED PLENUM BELLY PAN (ALUMINUM), REPLACED GASKETS, CAP, ROTOR, TPS, MAP SENSOR, IGNITION COIL, SPARK PLUGS (AUTOLITES 3923), VACUM VALVE, ALTERNATOR, IDLE PULLEY, ALSO COOLANT FLUSH, REROUTE THE WIRES, COMPRESSION CHECK, OIL/OIL FILTER CHANGE, RESET (P0301,308,300) CODES.

I had the Bosch plugs the first time around and that was a mistake (fouled two within the first 5 miles then the codes came back).
It appears that was source of the codes till I replaced them with the Autolites. The oem belly pan was warped and would not seat flat on the plenum even with the bolts installed (no gasket) I was getting up to .004 in between the two. The truck is running good now and not rough or galloping at take off.
Here are some pics on the plenum pan fab and gaps I mentioned.

 

Great job, looks very good.
Shoulda done the kegger mod while you were in there though.


Is that a Viper I see there?!


BTW, why is your PCV in the wrong spot??

 

Yes, I could have done the kegger mod but I needed to get the truck up and running asap. My PCV has been there since day 1 where should it be. Does it really matter?
And yes that is my pet snake. 06' Dodge Viper SRT10 convertable.

 

The pcv valve has been moved around by Dodge a couple times. Doesn't matter where it is as long as it's not on the same side as the breather tube or breather in your case.


Nice car btw, you should modify the hood and stick it on the Ram Actually, since the Ram hood is so big, you could use it as a hood scoop. LOL

 

[BTW, why is your PCV in the wrong spot?? [/quote]

I just saw a pic of one out of the manual that was non-california configuration. I think that's why mine is on the opposite side.

 

Nice ride man...ohh I'd love a viper...

My pcv valve is in the back of the cover, on my 94 at least...and while looking at it, I noticed a SECOND oil fill cap there?!?!?! Is that normal or the PO put a cover there that don't belong on that side??