Kind of long so please bear with me. Great forum btw, lots of info here.


Been lurking for a while but now it’s time to get started rebuilding my truck, so here’s the situation and looking for opinions.
First off, 1995 Laramie SLT 4x4, 5.2L, 205XXX miles on the original tranny and engine, and it’s my DD. Bought this for $2G with about 140K miles on it about 4 or 5 years ago.

Pretty much need to rebuild/replace well…everything . I still get about 15-16 mpg, heater core is starting to trail off, got some vacuum check valves that need to be replaced, plenum of course (uses about ½-1 quart of oil between changes, every 3-5K miles Castrol GTX high mileage), tranny could shift a little better but it’s not too bad (it’s been serviced with oil/filter 2x as far as I know). Transfer case has cracks (snap ring bad maybe?), exhaust rattles (bad cat I assume or heat shield), but other than that, she still runs pretty well.

I have replaced brakes (calipers, rotors), water pump, radiator, tranny check valve delete, external T-cooler, rear drive shaft u-joints, and rear diff oil change.

Now, the plan:
1) Since this is my only vehicle, I assume I should start with the transfer case because if that goes I’m SOL.
Cracks look just like this https://dodgeforum.com/forum/2nd-gen...se-pics-4.html

Any chance a saver ring would extend the TC life or should I not worry about it and just replace the whole thing? Since the case is shot, where a good place to get a whole new one or at least a new case with a rebuild kit?

2) Exhaust: Either the Cat is toast or I have a loose heat shield, or that is what it sounds like. Probably a trip to the muffler shop with a high flow cat as I don’t have welding equipment, unless gutting and brazing is an option (I’m guessing not worth trying)? This brings me to the plenum since I don’t want to ruin a new cat. Oh yeah, and a new O2 sensor.

3) Plenum: Hughes kit or Hughes F1 air gap intake. This is where the fun begins. I really like the idea of using the air gap but in doing so how do I specifically deal with the EGR? Is this an intake modification? If I EGR delete is there a write up with pics on how to do so? I really want to avoid CE lights and don’t want to mod the intake unless absolutely necessary. This might be easier to deal with than I am making it out to be but I want to make sure I have my bases covered since this is my only vehicle and can’t have major down time.

Probably a good time to replace the timing chain and front seal at the same time?

After all this, then I guess I start saving for a rebuilt transmission and then on to specific engine mods if I choose. Where is a good place for a 46RH rebuild, either online or East TN area?

Thanks for any thoughts.

 

Replace the transfer case. That one is toast. Get the T-case saver anyway, install it in your new case.

does hughes offer the air gap with provisions for egr???? ( I haven't checked, as I have no intention of spending six hundred bucks on a manifold......) The M1 comes in both flavors, I think, but, that is a single plane manifold.

Do the water pump, timing chain and gears, front crank seal, all in one go. You can do it at the same time you are doing the plenum, it is just a handful more bolts..... but, make sure you budget some extra time for 'unforeseen' problems. (broken bolts..... I broke two on the intake, none when doing the water pump.)