Nice...I would also think about a new radiator fan clutch if not too expensive.
Yes thermostat.
Going to need some gaskets
Inspect torque converter flex plate for cracks.
Belt or belts
Idler pulley
new vacuum hoses

If it makes you feel any better, I spend more money on mine in parts than the whole van is worth and do all my own work.

 

Thanks! I'm going to get started on the exhaust system this week. It looks like dropping the whole exhaust might be easiest. Are there gaskets that can be changed in the exhaust manifold flange?

 

Shows here yes but Im not 100% sure. Some of my old Mopars were metal to metal between manifold and head.
https://www.rockauto.com/en/catalog/...ld+gasket,5400

 

Yeah, maybe that's the case. I couldn't find gaskets anywhere, but I have a leak at the flange... I'll see if tightening things up helps.

 

I found this under the van after doing the bearings. Looks like a vacuum hose. It came from the middle passenger side of the van. At least that's where it was laying. Any idea where it came from?

 

Regarding the exhaust flanges, from the manual:"The engine exhaust manifolds on gasoline engines are equipped with ball flange outlets to assure a tight seal and strain free connections."

 

There are round ends on the exhaust manifolds to exhaust pipe connections, mine is a 1999 5.2 and the pipe has a flare on it but no gaskets there.

 

...and now this... new muffler installed.

Only problem is I need an adaptor from the exhaust pipe to the catalytic. I need something to join that pipe to catalytic converter which requires 2.5" OD to the exhaust pipe. Something like a 3.75" OD to 2.5" OD adapter.

Can anyone confirm the diameter of the exhaust pipe, the end opposite of the manifold flange? Couldn't find it in the manual or find a stock replacement to reference... I searched for everything I could think of and can't find an OEM replacement for the y pipes that go from the manifold to the catalytic converter.

 

My bad. Was thinking I was in the 2nd Gen Ram section.....

Pipe *should* be 3 inch at both ends of the cat, I think......

 

Thanks! Got the proper adaptors, but dang exhaust systems suck. Not a fun job.

Any ideas on what that hose is? I'm now getting minor backfires from the exhaust manifold area. Wondering if that has something to do with it...