Just got my new Hughes plenum fix, going to be doing it this weekend. I've made a small list of items that I'm gonna be needing:
[ul][*]in. lb torque wrench[*]extra coolant[*]rtv sealant[*]quickdry gasket cement (for front and rear seals)[*]Fuel injector removal tool[*]Intake cleaner [*]Tap (to clean threads)[*]Gasket removal solvent[/ul]

Am I missing anything? Thanks

 

when your all done come on up and tackle mine please lol

 

The little bypass hose from the intake to the water pump, I cut mine off .....It's smart to grab a new one IMHO. I just read your sig though and you did the thermostat already so maybe you already replaced it then.

Does the kit come with all new bolts? I bought new ones from the dealer and cut the heads offand made a slot infour old ones to use asstuds to help align the intake when putting it back. I ended up only using two on the front as the distributor was in the way at the back. I'm not sure if you need thread locker for the lower plenum bolts in the Hughes kit or not? I did for the standard setup.

I broke a bolt head near the front and it was a major PITA to drill it and tap it ....I got lucky and survived it but I broke a few bits...lol I would probably soak them with PB blaster or something first now that I know they are VERY weak.

You don't actually have to remove the fuel rail and injectors,only the line that connects them. I took mine out thinking I would replace the O rings but once I found out the price of those little suckers I inspected them real close oiled them and put them back with no problems.

I used a fine brass brush on a die grinder to clean the gaskets off ....I don't have much luck with that gasket remover stuff.....I use brake cleaner to clean things but its expensive.

 

use a thread chaser not a tap. A tap always removes material, a chaser only cleans the threads

 

You don't need to pull the injectors, but you may need the wrench for fuel line fitting.
Hughes recommends lock tighting an torquing the plenum bolts.
Be a good time to replace any old heater hoses too.

 

982500 Ram: yeah the kit comes with new grade 8 bolts. I'll remember the PB blaster then. I've already had bad luck with breaking bolts, I ended up breaking some when I put the headers on. I've never used gasker remover but the Haynes manual said to try it, but I have good luck with elbow grease! Hughes said to put some thread locker on, and I've got some. I'm grabbing some intake cleaner to spray the inside clean. I like it a little better then brake cleaner.

Isthere any other thing I should watch out for?

 

Does the kit come with new bolts for the topside as well? The aluminium ones? They are the ones you need to replace they are only meant to be used once and they will be in poor shape if they are anything like mine were.

Ya I used intake cleaner inside it too. I just like brake cleaner because it dries so fast and I'm only slightly patient....lol the plenum gasket was baked on real good so elbow grease is the only answer there...I'm sure you already know not to dig into the intake at all as you scrape.

I actually just used an old bolt after I put it on the wire wheel and greased it to clean the threads. I just re cleaned it before every hole and made sure it went in nice and easy.

 

Yeah new bolts all the way around. Alum. and ones for the new pan too.

 

I had to replace the small plastic dowels for the front and rear intake manifold gaskets as my new set came with cork front and rear gaskets while the one I replaced had plastic gaskets with built in rubber *****. Make sure you clean the two front and two rear holes completely before installing the dowels. For the small plastic dowels I borrowed some of the scrap plastic from my sons car model and cut them down to size.

 

I'm getting a ft. lb torque wrench from Summit, any excuse to buy new tools. Where did you guys get your in. lb wrenches at? I'm wanting to buy one at a decent price 50 r under.