Sure enough there is oil at the bottom of my TB. I must change the plenum gasket before my engine pings itself to death.

From the TSB(should be all the parts right?):
For the 5.2L / 5.9L:
1 04897383AC Package, Intake Manifold Flange Gasket and Bolts
1 05017208AA Gasket, Intake Manifold Plenum Pan
15 06034583 Bolt, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body'
2(AR) 04318001 Conditioner, Combustion Chamber

Is it necessary/recommended to change those 15 plenum pan bolts?

DIY by steve00ram360, looks helpful.

Should I also go to a 180 thermostat?
Is there anything else that I should be looking at while I'm taking the engine apart? Gunna get started tomorow afternoon.

 

Change the bolts. I used to laugh at changing them; however, I had a lengthy discussion about this with my father, who is a retired engineer, and he told me the following:

Engine bolts for the heads, intake, and other parts are torqued with a certain amount of force. Nowadays, you will never find a washer on these bolts, because Detroit engineers have learned, over time, that the torque negates the need for washers. Now, there are so many forces at work that the bolts undergo a tremendous amount of stress. Over time, the bolts actually will become distorted and elongate. The elongation will not be visible to the naked eye, but again, the engineers have analyzed the bolts under extreme magnification and used special equipment to measure the length of the bolt, which indeed does change. Re-using the bolts (could) be a potential problem; therefore, it's best to replace the old bolts.

I have learned a lot from his engineering knowledge when it comes to the design approach to vehicles.

 

Thanks VWandDodge that was a good explanation. New bolts it is, especially after so many miles. I'll make sure to get the torq specs just right. Sometimes it's better to know an good engineer rather than a mechanic.

 

Don't get the kit from the dealer! It will happen all over again. Go to http://www.apsprecision.com and get the plenum from them. Its probably alot cheaper then the dealer too.

 

So DC hasn't revised the kit to offer a correction? That's pretty bad. I'll consider the APS because as you say the price is probably better and it's 6061 Billet Aluminum 1/4". They offer a complete kit that has : Billet Plenum Plate Deluxe Kit - 1992-2002 Dodge Magnum V8 (5.2/5.9L)
Includes Intake Manifold Gasket Kit and new Intake Bolts... all for $140. Guess I'll have to wait abit and drive easy. Thanks for the suggestion.

 

They're much better then factory

 

change the bolts, .25 ea. you should also get a felpro gasket p/n ms95462 summit has them for about $17 bux but you should be able to find them local for about $14 bux.

 

Not trying to hijack this thread but I was reading the TSB that brute98 posted the link to and it listed 1994-1999 models with the 5.2 and 5.9 being affected. Was the problem fixed for the 2000 and up or is there another TSB for them too? I have the 2000 with the 5.9 and wasn't sure if there was still a plenum problem or if I lucked out this time.

 

the only way to get this fixed correctly is to get an aluminum pan & a felpro gasket. I used the stock pan with the updated gasket, new bolts and it still leaked. I used the aluminum pan with the updated gasket and it still leaked. currently the alum pan with the felpro gasket is holding just fine