Dodge Magnum V8 Intake Plenum Pan Gasket Replacement
PS: Sorry for the silent film. After all the work, I forgot to add music.
If your Dodge Ram, Dakota, Durango, or Jeep Grand Cherokee (ZJ) with the Magnum 3.9L V6, 5.2L V8, or 5.9L V8 has been pinging during acceleration or under engine load, and using/consuming oil, then more than likely your Intake Plenum Pan Gasket has blown out and is allowing the engine's vacuum to pull oil from the valley (where the camshaft/pushrods are) into the engine, burning it and causing ping/spark knock. The plenum being one piece, instead of a separate upper and lower intake manifold, requires there to be an opening on the bottom of the plenum during casting since it's such a large piece of aluminum. The solution is to cover it with a pan, as such. The pan is made of very thin aluminum and over time it warps from heat, allowing the gasket to blow out. You can replace the gasket but since the pan is warped, it will only blow out the gasket again and since it's so much work, it's not fun to do it several times. Hughes Engines has a replacement pan that is much, much thicker and is the solution to the warping. It will not warp and the gasket will not blow out again. This is the kit that I used in the video/slide show. It was cold out when I did this a few months ago so I didn't take any video, just pictures. Sorry the video is silent. The kit for the 5.2/5.9 V8's can be found here: http://www.hughesengines.com/Index/products.php?partid=22220
and the kit for the 3.9 V6 can be found here: http://www.hughesengines.com/Index/products.php?partid=22078. By the way, I'm not endorsed or sponsered by Hughes engines, I just highly recommend the kit if you're going to put in the work to replace the gasket. If you have any other questions about the procedure or any other repairs or questions about your Dodge, Chrysler, Jeep/ Mopar product, just send me a message or leave me a comment.
This applies to all '93-03 Dodge Ram, Ram Vans, Dakota, Durango, Jeep Grand Cherokee with the 3.9L V6 (239), 5.2L V8 (318), 5.9L V8 (360).
As always, disconnect the battery, and be safe and careful with yourself and everything under the hood during this repair. Thanks for watching! Comment, Rate, and Subscribe!
94-01 Dodge 5.2/5.9 Hughes Performance Plenum fix 1 of 2
Video 1 of 2 My first attempt at this video thing.I usually record these
just for my own use to aid in reassembly when doing repairs.I apologize for
the poor editing and camera angles,as I recorded these with my smartphone .
I hope someone will benefit from this.The repair is installing the Hughes
plenum pan/gasket kit ,you can get this kit from their website .The vehicle
is a 99 Dodge 1500 4x4 5.2 .Thanks for watching.
Part II https://www.youtube.com/watch?v=P6CeusX94SU
How to tell if your plenum pan gasket is blown
This is an amateur demonstration of the Chrysler-recommended diagnostic
test to see whether the Dodge Ram/Durango/Grand Cherokee plenum pan gasket
has failed, as described in TSB 09-05-00. Issues of test sensitivity and
specificity are raised.
A common flaw seen in the Dodge Ram Magnum V8 engine (1994- approx 2003) is
a leaking plenum pan gasket. The gasket is said to be prone to failure
because the pan is made of steel, and the intake manifold is aluminum. With
the different coefficients of expansion between these two metals, and the
marked thermal change this area is subjected to, gasket failure is quite
common, leading to an internal vacuum leak and oil contamination of the
intake manifold. Failure of this gasket may lead to oil consumption, poor
gas mileage, pinging under load, and rough idle.
This is a demonstration of amateur effort, published in good faith but with
no guarantees as to safety or accuracy. Auto repair is intrinsically
dangerous and misadventures are to be anticipated and planned for. Do not
try this at home without professional advice! Any misadventure you
encounter if you should decide to try and repair your vehicle is your
Thunderclap sound used under Creative Commons 3.0 license, done by
RHumphries at http://freesound.org/people/RHumphries/
1999 Dodge ram plenum repair
Fixing the plenum pan on my truck... its a common problem on 2nd gen dodge
rams. When the gasket blows it lets oil into the intake which gets sucked
into the cylinders... most trucks mine included were just re programed to
run diffrent instead of dodge fixing the plenum. After replacing my plenum
pan and intake gaskets, i have more power and it hasnt used any oil or
coolant in the past week.
Bye Bye Transmission...
dan running his truck threw the mud out behind the barn. guess the
transmission was going to go eventually considering it had 200,000+ miles
and hauled horse trailers most of its life. but it drove in and it drove
out all on its own.
heres a little info about the truck:
1999 ram 1500
4 inch suspension lift
dana 60 front/ dana 70 rear
gutted cat into flowmaster muffler all 3" pipe.
tires are 35x15 interco tsl boggers on 16.5x12 MT classic wheels
How To Find A Vacuum Leak - EricTheCarGuy
Vacuum leaks are one of the biggest causes of engine performance problems.
This video is pretty straight forward in it's approach to finding a vacuum
leak. On thing I might mention is that not all vacuum leaks are at the
engine. Some HVAC systems run on engine vacuum and can cause a leak under
the dash in some cases. I've even seen vacuum operated door locks. Just be
sure to be careful spraying flammable stuff on a hot engine, you don't want
to take one problem and make it a whole lot worse. You can also use a spray
bottle with water to do this same test. It may not be as effective, but you
don't have to worry about spraying a flammable substance on a hot engine.
For more information on diagnosing engine performance issues, check out
this article I wrote.
The best place for answers to your automotive questions:
Information on Premium Membership:
Due to factors beyond the control of EricTheCarGuy, it cannot guarantee
against unauthorized modifications of this information, or improper use of
this information. EricTheCarGuy assumes no liability for property damage
or injury incurred as a result of any of the information contained in this
video. EricTheCarGuy recommends safe practices when working with power
tools, automotive lifts, lifting tools, jack stands, electrical equipment,
blunt instruments, chemicals, lubricants, or any other tools or equipment
seen or implied in this video. Due to factors beyond the control of
EricTheCarGuy, no information contained in this video shall create any
express or implied warranty or guarantee of any particular result. Any
injury, damage or loss that may result from improper use of these tools,
equipment, or the information contained in this video is the sole
responsibility of the user and not EricTheCarGuy.
5.2 ZJ Hughes Air Gap Intake & Big Gulp TB Dual Exhaust Cam
I finally installed an Air Gap Intake Manifold and Big Gulp Throttle Body.
The Top-end and Mid-range of the power band have improved dramatically. I
am very happy with this purchase.
List of Mods:
5.2 Magnum rebuilt bored .030 over
Comp Cam P/N 20-602-9 (206/210 Duration, 112 LSA, .480" in .512" ex lift)
Crane 1.6 Roller Rockers
Mopar Timing Set
Mopar Valve Springs with .600" shims
Hughes Engines/Edlebrock Air Gap Intake
Hughes Engines Big Gulp Throttle Body
K&N Cold Air Intake with IAT sensor installed on it (Air Gap doesn't have a
spot for it which you're told :D)
K&N Air Filter
2.5" Stainless Steel Piping Welded to the headers leading into...
Magnaflow 2.5" Stainless Steel True Core X-Pipe leading into...
Magnaflow 2.5" Stainless Steel Dual In/Dual Out Muffler leading finally
Magnaflow 3.5" Stainless Steel Tips
MSD Digital 6A Ignition Box
MSD Blaster 2 Coil
MSD 8.5" Super Conductor Wires
OEM Champion Spark Plugs
Stock ECU (due to fuel prices, I do still have the Mopar Performance ECU.
The 5.2 would probably push 300 hp and 360 tq with that on now! WILL TEST
Stock Transmission (180,676 miles and still fine!)
242 T-case (Selec-Trac) out of a 97 GC
KEENAN'S KUSTOMS 99 DODGE DAKOTA PROJECT HD
THANKS TO ALL THE SPONSORS AND EVERYONE INVOLVED IN THIS PROJECT. HUGHES
ENGINES (KEVIN), MOROSO CUSTOM OIL PANS (TIM), COMPETITION ENGINEERING
(DOUG), MAG-HYTEC (JERRY), A&A TRANS (PATRICK), PERFORMANCE INJECTION
EQUIPMENT (CHRIS), PACE EDWARD'S (JODI), BODY CODDINGTON (DELT WITH
DAUGHTER), SPINTECH, MSD, FLOWKOOLER, MCKINNEY CHRYSLER/DODGE/JEEP PARTS
DEPARTMENT (BEN), GRIFFIN CUSTOM RADIATOR (RIGHT DOWN THE STREET PIEDMONT
SC), SIDEWIDERCUSTOMS (DARREN), EVERYONE! IF I MISSED YOU LET ME KNOW
ABOUT TO FINISH THIS PROJECT AND MOVE ON TO NEXT. FATHER WANT TO GET INTO
WRAPPING - GOT 2008 300C NEXT IN LINE FOR HIM.
KEENANS KUSTOMSS 99 DODGE DAKOTA
474.4 SMALL BLOCK BIGGEST EVER BUILT BY HUGHES
426 STROKER K1 TECHNOLOGIES (CORRILLO) AND CONNECTING RODS 6.125"
CUSTOM DISH PISTONS AND PINS 4.225"
BLOCK - R3 MOPAR SIAMESE 4 BOLT MAIN RACING BLOCK
INTAKE - HUGHES F1 AIRGAP, INTAKE MANIFOLD WITH CUSTOM FUEL PUMP,
RAILS, AND LINES CHRIS (PERFORMANCE INJECTION EQUIPMENT)
THROTTLE BODY - 1050CFM / 55MM
HEADS - HUGHES MODIFIED RT STAGE 4(NEW) ASSEMBLED WITH RACING VALVES,
2.055 INTAKE AND Exhaust 1.650,
COMPRESSION RATIO: 10.7:1
ROLLER ROCKERS - 1.6:1 RATIO - HUGHES
HYD. ROLLER LIFTERS
CAM - HUGHES
ECU - HUGES HP STAGE 3/ WITH 3 TUNE SCT SCANNER CHRIS (PERFROMANCE
AIR BOX - MOPAR HP WITH HUGHES CUSTOM AIR FILTER
CUSTOM HEADERS SPINTECH 1 7/8 PRIMARY WITH PORT PLATES
MSD IGNITION COILS
GRIFFIN CUSTOM RADIATOR
FLOW KOOLER PERFROMACE WATER PUMP
MOROSO CUSTOM HP OIL PAN
DUEL REMOTE OIL FILTER.
A&A CUSTOM 518 TRANS 3200RPM 9" BILLET STALL CONVERTER, CUSTOM BUILT FOR
468 CUBIC IN. BUT THEY SAY IT WILL DO THE JOB.
MAG-HYTEC COOLING DIFFERENTIAL COVER
COMPETITION ENGINEERING SLIDE-A-LINK TRACTION BARS
MCKINNEY DODGE/CHRYSLER/JEEP BEN IN PARTS VIPER BRAKES
SIDEWINDERCUSTOMS VIPER BRAKE CONVERSION KIT
BOYD CODDINGTON CUSTOM WHEELS
TOO MUCH TO NAME
RUNS OFF REG 93 OCTANE!
Dyno AT HUGHES WITH NO
SPECIAL STUFF ADDED ON. JUST CARB RAN
3300 RPM 569.0TQ 357.5HP A LITTLE ABOVE IDLE!
5300 RPM - 603.5TQ 609.0HP
Travis Keenan (CFO)
KEENANS KUSTOMS THE STANDARD BY WHICH OTHERS ARE JUDGED
attn: TRAVIS firstname.lastname@example.org
400 WOODFIELD DR.
PIEDMONT SC, 296736
Seller: keenanskustoms864 -Pace Edwards Truck Covers
SC Distributor: http://www.heatshieldproducts.com
Search: Travis Keenan or email@example.com
NOLOGY HOT WIRE DISTRIBTOR
PERFROMANCE ANALYSIS DISTRIBTOR
PRO CHARGER DISTRIBUTOR
SLANT 6 Mopar or No Car!
Mopars and very attractive women.....Mopars Kicking ASS! What more can you
If you like what you hear, come and visit me at CDBaby!
In case anyone is curious, yes, I've owned tons of Mopar products! There
is a SRT4 in my driveway right now. I've had Coronet R/T's, Challenger RT,
Demon's, 300's, SRT8's, I love em all! And I have no problem with other
cool Musclecars. I even own a Buick with a V6 that is fairly
quick......However....I loves me Mother Mopar!
I'm back in the old school! I have a "NEW" 70 Coronet R/T! Burnt
Orange/White interior numbers matching, bla bla bla bla!!! Will post pics
of it in my new Mopar song. Yeah, I'm doing another one, yeah I'm corny!
Actually 2 tunes. One, I penned back in the mid 80's called Red Light. It
was about my 69 R/T.