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  #1  
Old 06-02-2012, 07:57 PM
2kram 2kram is offline
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Default intake plenum gasket

It's been a week since i tackled this job, and all i can say to you guys is " thank you for the Hughes plenum fix". Sorry no pics, no digital camera ...yet. If anyone is on the fence about why not wait should do it almost immediately. No more oil consumption, no fouled plugs (#7-#8). While doing this project i also changed cap and rotor, i still cant figure out how it even got any spark, cap looked like a charcoal grill. Now with the $ i will save on buying oil, i will get to the exhaust alot quicker.
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Old 06-02-2012, 10:40 PM
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cape99ram cape99ram is offline
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were u getting a strange whistling/whirring noise when the plenum was bad? ive been noticing one in my 5.2 under light acceleration and there was a little oil in my intake by the air filter.
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Old 06-03-2012, 07:33 AM
2kram 2kram is offline
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Sorry no noise of whistling. For the whistle try checking to make sure throttle body to manifold gasket is still good. Hughes has this gasket in the kit, hint hint nudge nudge. Also check the " air filter mounting gasket", the 5" round one on top of throttle body, and make sure that theres a good seal between the two. I had the classic signs of oil consumption, pinging under acceleration, and w/ engine OFF i manually opened throttle body to view oil residue inside the intake/plenum. When mine came apart i could not find where the gasket leaked from, but definately caked with oil
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Old 06-10-2012, 07:16 PM
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i had a feeling that was gunna be the problem... cuz i have a little oil in there too and i have a misfire... hopefully thats the problem cuz injectors suck on these trucks. where do u get the hughes kit??
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Old 06-24-2012, 03:39 PM
spockmckoy spockmckoy is offline
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Cool hughes kit..

Hi,

I began to tear my 5.9 apart Sat at 5pm. I had to stop at 9. The last thing I did was get the fuel rails off. I have to tell you, I pulled my azzz off! wiggled/pulled and they finally let go, but on the drivers side, 2 stayed in the engine. Are new O ring kits available for these injectors? Today I continued working and got the plenum off and began the cleaning process. I have so much sludge in my plenum. I did the soak route to clean, though now the aluminum is discolored. I used simple green and some purple cleaner (from wally world) that did say avoid 'prolonged' contact with aluminum, but did not state how long 'prolonged' contact is. It appears 1 hour in all hot water in a slop sink may be too long. I will say every bit of sludge floated to the surface though! bubblin goo...... I used 1/2 gallon of green, and 1 gallon of purple in full tub of hot water. Also, when I read about looking in the throttle body for signs of oil, does 'sludge/tar' count? lol. It was loaded. I have 53,000 miles on my 02'.
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Old 06-24-2012, 03:55 PM
spockmckoy spockmckoy is offline
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Angry broke bolt...

I almost forgot, while removing the old plenum, the very 1st bolt broke off in the block. All others came out fine. Now I have to find a way to drill/tap for the new Hughes bolts when the time comes. Not looking forward to that....... I still have to clean all gasket material off the engine, then drill/tap. I'll have my little vac running to suck up any metal as I go.
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Old 06-24-2012, 06:22 PM
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I had to do one on a Jeep and a bolt broke. Be sure to get the bit centered and use the reverse titanium drill bits.
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Old 06-24-2012, 08:10 PM
spockmckoy spockmckoy is offline
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never heard of reverse drill bits? Where did you get them? OR is this a joke? I've used 'easy outs' with the reverse twists and they usually break easy.
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Old 06-24-2012, 08:15 PM
spockmckoy spockmckoy is offline
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Default found a set...

I did a quick search and found a set on Amazon......ordered.... d)
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Old 06-29-2012, 05:24 PM
XYZsniper XYZsniper is offline
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This thread has motivated me to tackle the job. I just did the transmission and new exhaust and was bummed to see oil down through the throttle body.
Not sure if bad or good, but its used about a quart of oil in the 600 miles its been on the road. Runs a little rough and once warmed up, idle will fluctuate at stop lights.
So anyways, gonna do compression check tomorrow morning and then start tearing into it. My plenum kit should be here 7/3
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