Yep, read the sticky.

Here is my part list, am I missing anything? Should I replace the EGR valve and or MAP sensor while I have it torn down? NM on the MAP, will keep the old one.

Hughes Plate Kit (intake gaskets with the kit are good right? or should i use different?)

Hughes TTY intake bolts

Belt Tensioner

180 Degree Superstat

Valve Cover Gaskets

Throttle Body Gasket

Oxygen Sensor

Distributor Cap and Rotor Kit

Temperature Sensor

Timing Cover Gasket Set

Injector O-rings (2 per each)

Idle Air Control (IAC) Valve

ETA: Timing Set Gears/Chain

ETA: By pass hose

ETA: Dealer PCV Valve

ETA: Fel-Pro Intake Gaskets

Valve covers have a leak, so that's why they are getting changed.

thanks for any help you can give.

 

Don't need to take the valve covers off, or the timing cover unless you're planning on changing rockers, water pump and/or timing set. Not sure why you'd need a new belt tensioner. Good time to replace PCV valve though. You'll probably want a bypass hose and maybe some heater hose since you may have to cut them off.

 

The MAP sensors on these trucks are regarded as near bullet-proof, so probably no need to replace it. Can't help you with the EGR decision, but I can tell you that some folks just block it off completely.

It's generally considered a good time to replace the timing set as well... you're gonna be right there any way.

Once you get it off, inspect your water pump thoroughly (pay particular attention to the shaft/pulley bearing).. if it shows sings of imminent failure, replace it as well.

 

For me, the plenum repair was a big enough job that I didn't want to deal with the time set/water pump replacement. And really, it's easy enough to take the ac/alternator assembly apart later another day. Especially for me because I have an e-fan and don't need to mess around with a shroud.

 

I just ordered part of my parts list for this job so I will throw my two cents out.

I have read post where others do not recomend using the gasket with the Houghs plate kit but would rather use Fel-pro intake/plenum gaskets. As I recall the Houghs kit was around 120 plus the need for a 25 dollar gasket kit so roughly 145 for the parts. I found a place on EBay selling a 1/4 inch aluminum plate with hardware for 59 bucks and I sourced the intake gaskets from my local parts house for 24. I just received my plate today and looks like a high quality piece and in all I got all the parts fir half the cost. Just a thought to save you a little cash.

Jeff

 

yea if ur gonna do the timing cover gasket, might as well do the chain depends on the slack though, they will all have some play...
new valve cover gaskets is up to you since you say their leakin. a new pcv valve from the dealer aint a bad idea but if urs is still good then no need.
IAC you might just be able to clean and not have to replace it.
the belt tensioner is up to you if urs is bad or not, and also the temperature sensor and egr is a toss up to you but if their workin then why bother.same with the MAP.
all in all everything else looks good though. and i highly recommend a new bypass hose, cuz i guarantee that you will have to cut that one off if its the stock one. oh and really only need new injector o-rings if ur gonna pull them out. i left mine in when i took my intake off.

 

Talk about repair timing! Truck just threw Codes 12, 37, and 21 after lunch.

So that's, Torque converter solenoid, PCM disconnected?, and O2 sensor.

Wow, so all this happened after a 'fresh' tank of gas. Truck stalled around 2G RPM a few times but never died. I did add some heet and haven't had any more stalling.

It gets better, I had to drive through water up to the step bars last night to get home from the storms last night, I didn't have a choice on that one, and got another CEL, but the truck ran fine. Didn't get the codes on that one, but no CEL this morning, so...?

Should I be looking at changing out the both differentials fluid now (ASAP)?

Looks like the truck is going to hell in a hand basket quick...

 

also your gonna need some black rtv and blue lock-tite.
also spray down every bolt you think you need to touch with pb blaster. i did it everyday for a week before i did the plenum, did NOT have one bolt break!

FYI - the felpro intake gasket kit comes with a plenum gasket, and the gasket hughes sends out are also felpro, i bought both cause i read somewhere hughes gaskets were ****ty, now i have a spare plenum gasket i can sell a friend. lol

 

my hughs kit came with the victor-rainz (sp?) gaskets. although I always use fel-pro on everything else, I did use them. no issues yet. I did the kegger mod and really enjoyed this project. the only misstep I made was not realizing the furthest back intake bolt on the passenger side ( it's way back there ). oven cleaner worked best at cleaning the keg up.