I made some observations and took some measurements yesterday on my plenum. 4 of the washers on the factory bolts would not snug down to the face of the intake surface. The rest did. I use a feeler gauge and measured about .010 gap between the washer and the face of the plenum. Then I mic’d the thickness of the factory plenum to be .090 and with the gasket .125. In other words, there is a 1/64th gap filled with an 1/8th thick plenum/gasket. I would think that would be enough to hold the gasket in place. So maybe there’s something to the differential metal theory.

That said, all the bolts measured the same length. So it would appear that the depth of the holes machined into the intake were not consistent.

Notice that the worst failed gasket was between two good bolts. No failed gasket between “tall” bolts at bottom.

The bolts circled in red are the places where the washer on the bolt would not contact the surface of manifold before bolt bottomed out. Area in green highlight is where gasket failed.

This gap measured .010/.012 on feeler gauge.

 

I had the Hughes kit bolts gaskets and all and I don't know if upon replacing the intake the gaskets got knocked off or what but I still have the same problem. Using oil and not much power. 2001 ram 5.9 . Any ideas ?

 

Compression or leakdown test.

Also, how old are your O2 sensors?

 

Hey guys, new to the forum and dodge world.

just bought a 95 2500 5.9 v8. Drove it for about 300 miles on the highway home. I bought it from a buddy and he said it used a little bit of oil.. it used a whole fresh oil change on the drive home.

so I started looking into the problem and I stumbled across this.

i noticed the oil was being chewed through, the power on the truck is like a snail.

my question is once I’m in there is there anything you guys would say I should replace?

timing chain, headers, etc? What would you do...


1995 Dodge Ram 2500 5.9 V8 Magnum Stock no mods

 

Thermostat, timing chain (Clothes double roller), cap and rotor, crank sensor (if needed) any sensors on the intake manifold, radiator. I think that's it

 

thank you for the input. I think I’ll be getting these off of rock auto. $80 + or - and an additional $60 for the plenum plate. How long did this take you to do? 8-10 hours is what I’m expecting

 

About 1.2 hours it's a pretty simple job. Hardest part was the fuel disconnect, it didn't want to disconnect lol. I also meant Cloyes Double Roller timing set.

 

1.2 to R&R intake manifold??? Holy smokes. You are FAST. I spent around two full days doing the plenum and timing set..... Of course, I had broken bolts to contend with as well....

 

my god.. how can I get you down to southern Illinois to help with mine 😅

 

They was with a timing chain and water pump replacement. Come to PA and I'll help I love wrenching