I want to tackle it all at once, looking for a modified throttle body and egr 1995 intake manifold for a 5.2. I know a lot of people say DIY on modifying the intake, however, I'm not interested in cutting/grinding metal even a little bit, nor do I have the tools to do it anyway. I think $600 is a bit ridiculous from Hughes for theirs when I can find used intake manifolds for $16 at local boneyards, I just don't know of any machine shops (although I'm starting to look for some). Does anybody have experience with this? How much should I expect to pay a machine shop to do this for me? Would it be cheaper to find someone who has done a few of them and mail them an intake manifold?

As far as modifying the throttle body goes, what all is involved in that?

 

Throttle body is pretty easy, just take it ALL apart, and have your machine shop punch out the throttle bores to 50mm.. (if you go larger, you will need new throttle plates, and those seem difficult to come up with.....) If you look at the bottom of the TB, you will be able to see where the step is... around the plates, it already IS 50mm, it shrinks some above them.

Are you going to keep the EGR on your truck?

 

Awesome, thanks for the tip on the throttle body, good to know.

Can I remove the EGR, what would be some pros/cons with removing it?

 

You may or may not get a check engine lite for it... some do, some don't...... I think it generally takes a few drive cycles for it to set.... if it ever does.....

Not really much of a downside to not having it, aside from the potential CEL.... Dodge did away with it in 96 in any event.

 

And then stuck it back on some of the Hemi's........

 

Interesting, so to delete it; I can just buy a non-EGR intake manifold and search for EGR delete on these forums for any additional steps. By doing so my understanding is it will prolong the engine life, sound a little better and be slightly more responsive?

 

You could also just make a block off plate for the manifold to save you from having to switch manifolds.

 

Awesome, what material should I use? Can I use something I can mark with a sharpie and use tin snips with or is it a machine shop kind of plate?

 

U can make it but I would use something a little thicker than tin. I made one for a honda I had and used 1/8" steel plate. I just drew it out on it and cut it with a angle grinder and cut off wheel. Drill the holes you need to bolt it down and make sure to seal it with some high temp rtv.

 

i have the intake manifold off my 318 if u wanna buy it...