it just looks wet inside, cant really tell if its oil or gas

 

Smell it.

In all reality, there shouldn't be ANY gas in the intake manifold. If you see wet stuff down there.... your plenum is blown.

 

Yeah, LOTS of oil will be in there. Never had any problem with aftermarket PCV valves, so I don't think that would really cause oil pooling in the intake.

 

First off, I would like to thank all of the people who post on the Dodge Forum and especially those who posted endless good information about the plenum issues and what to do. I finally got around to doing the pluenum fix on my 2000 Ram 1500 5.9L. I installed the hughes aluminum plate, did the water pump, all new hoses, timing chain and all of the gaskets, tune-up filters and such. Total cost around $600. Spent about a total of 12 hours over Friday night through Saturday with a friend who is a car guy and has countless hours of tear downs and rebuilds of engines. It is always nice to have someone who can eliminate any doubts I have when doing these projects. For starters, had a ton of oil in the plenum, I literally poured it into the oil bucket. Gasket on plenum pan was perfect, when we started to tear apart the intake manifold, we noticed that the far back passenger side bolt was broken off on the intake. I have had the truck for almost 10 years and never had any work done on the top of the engine, so we have no idea what happened there. Cleaned all of the gasket surfaces to almost perfection, and I bought the felpro gaskets for everything. They have a nice raised rubber seal. When we removed the timing cover, noticed the factory chain had a ton of slack. Replaced with Cloyes double roller. The old crankshaft seal was worn and leaking a little. The shaft only had small wear marks, but nothing to be concerned about. Put everything back together including using a 180 degree thermostat and did the tune-up. Truck runs good. Now I need to deal with the Cat and my exhaust.

 

I've read a bunch of pages of this thread but can't find a straight answer.

I replaced the plenum with a Hughes kit this past winter but I guess something got messed up because the intake full of oil again... and was wondering if I can re-use the intake bolts and plenum bolts? Some say no bcuz they're TTY and others challenge that.

The only place around me that has either bolts are the dealership and they're somewhat far away. I'm gonna start tearing the truck down today and need to find out.

 

Did you replace the PCV Valve? You'll probably never get the same answer from anyone on reusing the bolts, just gonna have to make the decision yourself. Bolts are cheap from the dealer though.

 

Yup PCV was replaced with dealer part right after plenum was fixed. I thought the PCV would only put small amounts of oil near its opening on the inside of the intake? I've got a big 'ol pool of oil at the back of the intake...plus I think the intake gasket is leaking coolant. Either that or the timing chain cover.

 

Might be time to open her up again..

 

Had the local advance auto parts order the $50 dorman kit (gaskets, bolts, tsat, heater hose, etc.) arrived a few hours later. It's not the almighty fel-pro gaskets but it should do the job better than the one Hughes Engines gave me. We'll see...

 

YES! They are TTY! Any bolt that has a torqus spec is TTY..A thread chaser should be utilized as well as it will assist it attaining proper tourqe specs...spread the word!