[bmorris23]

I recently purchased a 1999 Dodge Ram 1500 with the 5.9 and I am having some trouble. I know, according to the PO, that the catalytic converter is clogged up (possibly due to the dreaded plenum-gasket problem?), it has had the transmission rebuilt, and the truck has been "deathflashed".

Is the cheapest fix, since Indiana no longer does emission testing, to cut out the cat and weld exhaust pipe in its place? Is this an acceptable solution to the problem? (Provided I remedy the plenum-gasket issues) What diameter exhaust pipe should I need, and what length? Also, what else should I be looking into on a high mileage (237 K) truck such as this?

The truck looks really nice inside and out, and appears to have been taken care of, and I really enjoy it. I got the truck so that I could use it as my daily driver, as well as occasionally haul my dirt bike (96 YZ-125 2 stroke). My Mom's car recently died on her (permanently), so I got this Ram and gave her my 02' Accord. I really need to make this last, at least until I finish my Nursing degree, and would sincerely appreciate any help and advice. Thank you for your time!

 

[JaimeZX]

If you don't need to worry about emissions, then I don't know why you wouldn't pull the cat. You might lose a little torque on the bottom, but I wouldn't worry about that.

This thing burns a lot of gas for a daily driver though... lol. I couldn't afford that. $100 to fill the tank for 12-14mpg?

 

[slimpartywagon]

just pull the cat down and punch a broom handle through it... and fix the plenum gasket

 

[gofishn]

just pull the cat down and punch a broom handle through it... and fix the plenum gasket

Winner Winner, ChickenDinner

 

[bmorris23]

Thanks, also...???

Thanks for the advice everyone! Am I correct in assuming that, when I do the plenum gasket fix, I should go ahead and do the plugs, wires, cap, rotor, thermostat, and coolant bypass hose? Is the Hughes plenum reinforcement kit (or whatever it is called) the best route to go? Anything else that I am forgetting that should be inspected and/or replaced/upgraded while doing the plenum job?

 

[slimpartywagon]

Inspect everything you take off, and yes it would be a great time to do a tune-up.

 

[bmorris23]

Nessecary tools, chemicals, et cetera

Ok, so I decided that I will order the plenum kit from Hughes, and everything else they recommend with it (tune-up parts, thermostat, throttle body gasket). I already have the Hughes repair manual for the truck, and the Hughes kit comes with instructions. Forgive my ignorance, but what tools and chemicals should I have on hand or rent to make this project run as quick and smooth as possible? I have basic tools such as a socket set, a tourqe wrench, a cordless drill, tap/die kit, and a mini-Dremel type tool in my garage. What, if any, specialty tools should I rent or borrow to help things run smoothly, or in case I have problems while underway? I only have three days off, and I am not the most mechanically inclined person but will take my time and can follow instructions. Any suggestions from those who have done this job?

 

[slimpartywagon]

you're going to need the fuel line injector removal tool... and other than that tool wise you are set... I like to have some engine degreaser, brake clean, and lots of rags on hand

 

[JaimeZX]

The $2 I spent on Amazon for a cordless drill hex-to-3/8" square drive is the best money I've put down on my engine project. Here, try this:
http://www.amazon.com/TEKTON-2902-Extension-Adapter-3-Piece/dp/B000NPT5YE/

Or similar anyway... I don't have an impact drill, but once I break a bolt loose with my ratchet, this pulls 'em out really fast. And putting 'em in anyway, the best my drill will do is 9-10 ft-lbs. So that, then torque wrench.

 

[bmorris23]

Thanks again everyone. When I dropped the cat, there was no honeycomb even in it to break up! Nothing but a little pile of dust. I ordered all the parts for the plenum reinforcement and a complete tune-up, a thermostat, et cetera from Hughes today. I think I am going to let a certified technician do the job, just to ensure it gets done correctly and on schedule. One tech quoted me 7 wrench hours at $60/hr, for a total of $420 in labor. Is this a fair price for these services?

 

[JaimeZX]

$60/hour was what I got charged 15 years ago. I would be happy if somebody charged me that now. Still a whole lotta labor $$ though. If this is your DD then I guess I'd do it; otherwise if there's something else you can drive I say DIY; it's not that hard.

 

[slimpartywagon]

Thanks again everyone. When I dropped the cat, there was no honeycomb even in it to break up! Nothing but a little pile of dust. I ordered all the parts for the plenum reinforcement and a complete tune-up, a thermostat, et cetera from Hughes today. I think I am going to let a certified technician do the job, just to ensure it gets done correctly and on schedule. One tech quoted me 7 wrench hours at $60/hr, for a total of $420 in labor. Is this a fair price for these services?

I charge 90 per hour shop rate, so that sounds more than fair..