I'm 63, recently retired due to lung cancer. Beat up from the chemo and radiation treatments but was able to BEAT the cancer, I'm not or ever will be 100% but I'm alive, lol. Also when I did this repaire I was seeing a chiropractor 3 times a week for a pinched nerve in my lower back. I took a lot of breaks, lol. About 10-12 hours over 3 days and now the truck is running great. No more oil use, increase in power, increase in low end torque, no valve clatter when accelerating, very smooth runnning. Not bad for an old beat up mechanic, lol.....makes me wonder how many people traded in their truck because they thought the motor was going bad, all over a bad design in the plemun sealing gaskets, lol... Probably a bunch of trucks in the salvage yard because of a bad gasket, lol

I still love the Gen 2, even with all it's issues. it's a GREAT truck! and you cannot beat it for the money. when they came out there was nothing like them, this truck pretty much kicked off the need for better trucks we have today, thanks Dodge. 263k miles and rolling strong.

Dude. I cannot thank you enough for this straight to the point video. I didn’t want to watch that other 6 part, 3 hour video to see what you Did in just half an hour. Thank you so much

Hands down the best video I've seen of this job so far.

First video I've seen of an actual tear down and replacement, thanks

Just found out today I need a plenum job. I plan on watching this video at least 10 times before beginning - great upload!

PSA - The original bolts are too long. Over time the oem plate gets thinner from heat cycles and age. From online forums, shortening/cutting the bolts is an alternative to the aftermarket thicker hughes plate. High temp rtv should be used as well. It works and save money!!

Great video. Thanks 👍 doing this project now with my 97 5.2

Great job very detailed 👏 need to do that in my 3.9 engine same problem thxs for sharing

I've done this twice; one on my own 2500, once for a neighbor. If you can obtain a helping hand, you can remove the intake with the throttle body together, just disconnect the bracket and cables at the throttle body. Use you cellphone camera to take pictures as you progress along if you need something to reference to. On the bottom plate it's helpful to mark the number sequence of the bolt pattern, that way you know exactly which one to do next. It's a three step torque pattern, you can use a sharpie pen to mark both the torque specs and bolt pattern to save time. You can remove the sharpie pen marks with carb cleaner, not that it's necessary as no one will see it once it's bolted in. Also, it's a great time to replace the distributor cap and rotor as they are now very easy to get to and the water pump by pass hose, since you already have to remove the ac compressor anyway and there's only a few bolts holding the bracket. Do it when replacing the pan, it only takes a few more minutes to do. Taking pictures will help you reference how things came apart and prevent mistakes later. I started doing this with a Polaroid Swinger B&W when I had no idea or guides to take something apart (BTW that was half a century ago).

Recently inherited my father's 2000 dodge couple of years back and had to replace the manifold gaskets, front main seal and harmonic balancer. She runs as good as the day my dad bought it. Just wish the dash frame wasn't so brittle.

Thank you for this detailed video. My son's ZJ is idling erratically and I think I hear a vacuum leak from the area around the intake. I think we are going to do this same repair together.

Nice job, however have done the same job on my 2001 Ram 2500, no need to remove the fan shroud, idler pulley and fuel rails with injectors, just unplugged all the connectors and took the throttle body off and accessory bracket with alternator and a/c compressor and moved it to the side then pulled the intake out pretty much straight forward, on my 1995 Ram 1500 I swapped out the factory intake and put on the Hughes FI Air Gap intake and was well worth the money and it is a much better intake, will be doing the same thing on my 2001 when it comes available again

Been trying to figure out why my 2000 Durango started using oil but had no sign of leak or smoke, now I know 👍🏻

Do you put silicone gasket maker when installing the intake manifold gaskets

In the past when I have worked on vehicles, when I have come across these rubber hoses, I have found that it is easier to remove the hose if you can get it to twist and spin on the fitting before you pull on it. It doesn’t always work, but seven out of 10 it will.

384000 miles on mine so far. second motor. second trans, seventh rear end and just now getting around to this on the motor. thanks for the help seeing this it dosent look as bad as i picture it is

Can you skip the regular gasket and just use gasket maker on the plate?

Thanks for posting. 👍

knock on wood my 96Ram 3500 V8 magnum is running great 150k doesn't smoke or burn oil yet but I drive her like a newborn baby ran great when I got it several months ago, but still did a complete full tuneup & changing every fluid and oil.

that kit included washers? or did you add them. also what gasket seal on the plenum did you use

Anyone know what the new length and size bolts are needed for adding the plate. Making my own plate now and wanted to get the hardware together. Also is just a washer used and/or lockwasher? Thanks a bunch in advance

Helpful video. Thank you !

Had a 2000 durango with the 5.9 V8 ran great for 300k miles. Engine Locked up on the road but before it finally gave out truck would have misfires, Lose power while driving and turn off had to set it in Neutral to turn it back on, high Revs without flooring the gas IdK why this happend but the truck kept going. Transmission went out at like 280k miles had it rebuilt. When I would remove radiator cap the fluid in radiator would buble during idle Im assuming that was a bad sign.

Can anyone help? My intake isn't sealing on the back end where the water ports are, its leaking coolant, I done the job twice and it's still leaking. Followed instructions, torqued down correctly, tried tighting bolts down more but made it worse, second time around I tried gasket maker around the ports but still leaked. What else can I do?

all gen 2 Ram''s need 3 things, no matter what! plenum fix(bad engineering), dash plastic replacement(FU Dodge), and that notorious front end wobble fix(FU again Dodge), all pretty easy stuff, but all necessary. you can check if you still have a stock plenum pretty easy, take off the breather, open the throttle, and use a magnetic pick up tool, or whatever you want, just don't lose it in there! and go thru the throttle body openings to see if the plenum is magnetic, if it is, you're probably still stock, and will need, or eventually need to replace it.

I'm watching this to remember how the accessory drive stuff goes back on and where the bolts go...its been a few months since I tore it down lol

where to get my plenum plate for my dodge 1994 the thiker one

Awesome job 🇺🇸😎👍

I wonder if the aluminum plate could be tig welded to the intake to guarantee no leaks ever again? Would it crack from welding heat?

Muchas gracias por tu video me es un exelente video de verdad muchas gracias

Thanks for your video. Looks like an all day job (or two) but I'm up to the challenge! I have a 2001 B1500 van with the Magnum V6 engine. This thing has a weird problem and I'm wondering if you can tell me if this plenum issue is the cause before I goto the trouble of pulling the plenum and doing this in vain and wasting $120 on parts. I have not done a compression test on the front two cylinders and looked inside the throttle body for oil yet but I am going to. I've heard you can also disconnect the PVC hose and if it has vacuum on it is a good indication the plenum gasket is blown. BTW, this was a used engine out of a 99 Dakota with 140,000 miles on it. The original engine had a rod knock. Long story on that. First of all the engine started blowing oil out around the top of the engine. I thought it was a front main seal, but I think it's that gasket between the engine and plenum. Next issue is the a few hundred miles later, the engine started to run awful. The OBD II reader says misfire on the front two cylinders and high voltage bank 1. I believe that means the exhaust is too lean. As if the unburned mixture from the front two cylinders are simply being pushed into the exhaust. I replaced the PVC valve and pulled the front two spark plugs. The electrodes were completely worn down to nothing just after 200 miles. I gave the van a tune-up about 500 miles before all this started. I did not drive it like this! Once again, long story. One thing I am NOT seeing is blue smoke out of the exhaust. But I did lose about a quart of oil after 200 miles. I'm not seeing any steam out of the exhaust like a blown head gasket. Any chance that the intake manifold gaskets are blown? But what would be the odds they would both blow at the same time on the front two cylinders? Another thing. This engine started to leak coolant a year prior from the driver's side around the plenum. I couldn't really tell where but it was up high. I put some stop leak in it and it fixed that but think the coolant leak and now the oil leak are related. Just based on those symptoms does it sound like I am in the right direction? Thanks.

Does this happen to the 3.9 v6?

You are an amazingly patient mechanic, my hat is off to You sir!! Thank You for this informative video. There is no way I could do what You do. I could be a great helper, fetch this or fetch that 😜 but that’s about it !

I thought my plenum pan gasket was blown three years back. I just needed a new PC valve on my 1993 318 Magnum with 192,000 miles I've had for 10 years. The Oil Pressure sensor gauge just started leaking oil. Making it look like a Rear Main Seal crankshaft gasket leak. Otherwise it's an amazing, reliable small block engine that never quits. Mine's a van. So I'm lucky to have a doghouse, tho. I can pull out the heads inside the van.

great job.

That small section of radiator line tubing is a simple trick, completely loosen both hose clamps or at least the bottom one put it up to the middle and pull the bottom half off first and it should come off no problem with your hands

channel locks are usually a good tool for removing stuck rubber hoses.

What type of wheel did you use on the air sander to clean the intake up with?

96 b3500 15 pass van. 404k HARD miles. ORIGINAL motor/trans and 1 rebuild on my rear end.. majority of its life spent pulling a work trailer. Other than maintenance I did a plenum upgrade I made myself from 1/4 aluminum. And when I first got the van at 50k miles I pulled the tranny cooler line and ripped the check ball out with a wood screw. Those check balls clog up over time stopping fluid flow and roast transmissions. Love my 2nd gen dodge. Tried breaking it time and time again, I just can't.

I recently bought a 98 ram 1500 if you're facing the engine towards the back right side of the engine near the air intake mine has a greenish colored plastic vacuum line any idea what that goes to or where it hooks up at? It has a decent vacuum when the motors running. My engine is the 5.2 (318) magnum with 4wheel drive Laramie SLT st

That was a lot of work wow my question is how do you know when to replace that plate?

Got a Question,got a 95Magnum318,The EGR Is Not Stumbling when I put Vacumn to it and it's keeping me from passing Smog,I'm a Mechanic Myself and I'm Stumped,Any ideas why it's Not Doing what it needs to,Cleaned All Passages and Installed New EGR...It's Giving Me Hell,Thanks,Great Video by the way,Thanks ✌️

Find it interesting the different types of repair jobs u do in the workshop

What can I use instead of the air spinner to clean the metal cerfaces

I was wandering my cylinder head is little loose and next to the cylinder head is leaking coolant so can u let me know what wrong I have any tips & i have 2001 Dodge Ram van 3500 5.9 engine I hoping I have to not replace big block engine

So i have a 5.2 and im hearing what sounds like a vacumm leak and traked it to the throttle body since i only heard it at a quarter throttle and inside the throttle body where the iac goes in i can feel the suction is that my plenum plate being cracked or the intake manifold gasket?

Is this same 5.9 found in ram van 1500 also same year...looks very similar...im no pro i dont know ...

Got a misfire 30mph and up with a 5.2 call a tech after I replaced a what I am sure is a OEM distributor cap and checked plugs and wires and still having a misfire, well I told him all of it and no check engine, said he didnt know but he'd start at timing chain. The TB had that same build up as you intake manifold so while I have the engine apart checking the tension of chain I'm going to tackle the notorious intake manifold gasket. Wish me luck that this stops my misfire issue

im experiencing burning oil coming from tail pipe, when u say eating oil i assume u mean burning and come through the exhaust ?

THANK YOU!!!! So, this kit comes with everything needed? link to kit?

I installed a new oil pump want to put a test pressure gauge where the oil pressure sensor is to actually see the oil pressure. Will the eng. run w/ the sensor out?

Does the guide not say to not use any rtv though? Just threadlocker.

Would this cause your oil to disappear and make it so thin that it runs down the dipstick when you're trying to get a proper reading?

I cut my own out of sheet aluminum and tig welded it, definitely never going to leak

At the 7:30 min did you mean alternator or starter?

Hey after doing this repair I have a lean condition and bogging down and falling all over itself when I give it gas. Think a gasket may have shifted on me while I installed?

While you were replacing the dist. cap ,you should have replaced the cam position sensor under the rotor button .If that goes bad the truck won't start .

Tha wrench is awesome 👌

I have 307K on my 360 with still good compression across all the cylinders but I'm down on power and burning about 1 quart every 1,000 miles. I liked the video and wondered if this helped restore your power and if it was noticeable. I'm hoping to avoid a full rebuild if I can and get a few more miles out of the engine.

I wonder why the intake manifold even has that cover on the bottom? Why not leave it like the la style?

How much harder to do it on a Ram van? I think this is what's happening to mine.

You needed to clean out the inside of that intake before you put it back on, dude.

Need to drain it to do plenum gasket?

can you pressure wash that oil off in the intake mani? and can you use an impact at all for this job?

Well I'm not about to pay some shop To probably not even do it right for me for 6+hundys wen me an some natural ice can get r dun some weekend in my future.. tired of adding 4 quarts every 3-4 weeks It's getting old and it's a fairly low mileage 03 quad cab dakota 5.9l I love her she does my fam good just drinks(burns) oil up lol Doesn't look like to much fun Fmt.. fml.. but thank you lord Also thanks for video Appreciate ya God bless

3M 07524 Roloc 2" x 5/8 Tapered Coarse Bristle Disc (Pack of 10) , Green LOOK IT UP!

I have the same engine, for what even reason my engine will Shut Off.. I am at Ends-Wits with it trying to move all wires around if possible to Shut Off. No Luck. Shuts Down without reason and will start up after 1 - 2 minutes without Key. Also, replaced many other parts and the same thing continues without any final clear fix..

Drill a 1/8 inch hole in the thermostat flange so it will self purge.

I let a mechanic work on mine once.. and they stripped that idler pulley but stuck it together with some goop.. MF'ers.. I helicoiled it. Smart tip about leaving the AC and Alt on the bracket then removing as one unit.

Can anyone tell me what are the risks of driving with a bad plenum gasket? I’m going to fix it soon but I’m wondering if I’m at risk of blowing the motor or something while driving it.

I didn't see you messing with EGR. I have a EGR tube bolted in the back of my intake.

Hell YEA

How did your egr tube come out?

Im sitting here Fighting for my life with that damn coolant hose. Its melded or something.. something aint right. I moved the clamp up so it aint catching but it still wont come off

How long did this take you to finish the repair?

Great job, what part of the country are you in ?

Those also eat oil because there's no baffle under the valve cover so it sucks up oil through the PCV valve so you should put one on it

Would you be able to email step by step instructions? Do I have to take off the alternator and the AC compressor and then the bracket or can I just take off the bracket? Also how does the fan come off? I’m 17 and wanna do this job on my truck but worried about not putting it back together correctly.

Not supposed to use Rolo'ks on internal engine parts!!! How long did the motor last after the '' FIX'' LOL ?

How much for a job like this

160$ for a 20$ aluminum plate 🤣...I went to the local fab shop and brought a .250 plate of aluminum. Took the old plate as a guide and made my own...works perfectly and Old Man Hughes is a dick..Not making him any richer 😁

i had to cut my waterpump to manifold hose like you said back in the day, even putting the new one back on was a bitch

I mean dam brutal with the hoses I guess the struggle is real. They make big boy picks you know now since 50 years ago that get hoses off in 2 seconds. You’re the guy who puts broken connectors back on ain’t ya? I just learned after 20 years to try the smarter route, but not always

how long did this repair take you

You're amazing! That engine, not so much. Thanks.

So did it solve the loss of power and oil consumption?

what was the mileage on that vehicle

A battery powered ratchet looks like it would sure be handy!

Have you had any problems with it yet

Dont mind the timing cover leak... they all leak there

Ball park $$ how much would something like this cost?

You should have went ahead and replaced the pick up plate with the cap and rotor. It will make a pretty big difference.

You must like doing a lot of extra wrenching .

Please; never ever use an adjustable cresent wrench anywhere near the engine bay, especially the battery area. How hard is it to reach and grab a 14 mm wrench? Lol 😂

Hey i just wanted to say i appreciated this up until "oh my camera died" At that point F U man FU but up until that 👍 cheers bro good on ya 😃

Can you tell me please; What is the torque of the PLENUM bolts that Hughes says to use?

Rob here....I put a 360 magnum from my 2000 Durango on my 1984 Dodge w350,just put an Edelbrock air gap intake on it with a Holly 4150 and a cam snout extension for the fuel eccentric. Now she purs like a kitten...

I did this repair with the aftermarket plate and the gasket still blew out 3 more times

When disconnecting a battery, ALWAYS REMOVE THE NEGATIVE TERMINAL FIRST, and connect it last when installing! Unless you enjoy the fireworks when the other end of your wrench on the positive terminal happens to contact any other bare metal on the engine or body.