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Unread Yesterday, 02:37 PM   #1
mudhawg93
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1998 ZJ 
 
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98 5.2 Plenum Gasket Replacement

Looks like my plenum gasket took a dump on me(not like I didn't see it coming), is it really worth it to spend the almost $200 on the hughes kit or am i better off just buying everything I need from my local parts store at the tune of about $61?

Does the hughes kit really THAT much to warrant the money spent?

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Unread Yesterday, 02:53 PM   #2
XJ93
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That all depends on how long you want to keep the Jeep. The Hughes kit is an almost perfect solution to the problem. Using standard parts you will eventually have another gasket failure, it's a design flaw. Personally I'd love to just replace the entire intake with the Hughes intake and never have an issue again. But that's $600 my wife would not like me to spend.
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Unread Yesterday, 03:08 PM   #3
mudhawg93
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Quote:
Originally Posted by XJ93 View Post
That all depends on how long you want to keep the Jeep. The Hughes kit is an almost perfect solution to the problem. Using standard parts you will eventually have another gasket failure, it's a design flaw. Personally I'd love to just replace the entire intake with the Hughes intake and never have an issue again. But that's $600 my wife would not like me to spend.
Well I plan on keeping the jeep for a long time, I would love to do the full intake as well.

The only issue is the 4 day or so wait to get the stuff from hughes and then waiting for 2 days off together lol

Sent from my S5 somewhere in the woods
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Unread Yesterday, 03:22 PM   #4
kg6mov
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There are ebay vendors that sell plates just as good as the hughes one. Then just buy the good set of fel pro gaskets and you're set.

http://www.jeepforum.com/forum/f13/n...l#post23796778
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I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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Unread Yesterday, 03:55 PM   #5
jm8881
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I recently got the hughes kit and replaced my plenum gasket and pan. The fact that it was an all in 1 solution was what sold me. All new gaskets, bolts, pan, everything needed to do the job without any trips to the parts store mid job.
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Unread Yesterday, 04:32 PM   #6
Snowfan2
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Save your money. I manufactured and sold plates until I read something over at the Dodge forum. The plenum bolts installed at the factory are too long and bottom out into the manifold before providing correct clamping force on the plate/gasket. Here is a pic that shows the bolt, bottomed out, without the plate---torqued to spec. Note that the space is about the thickness of the plate.
[IMG][/IMG]

All that needs to be done to fix the problem is grind a bit of the unthreaded portion off the ends of the plate bolts. Wipe both plate and manifold gasket contact surface with alcohol after thoroughly cleaning and coat both sides of your new gasket with black rtv. Done. Forever.

Don't believe the ridiculous 'dissimilar metals' theory, which cannot be proven. Sink your plate bolts into your manifold without the plate and see for yourself.
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Unread Yesterday, 04:37 PM   #7
kg6mov
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Interesting. I have read that mopar changed the gasket design for the later engines which is why the plenum failure is less common on newer magnums. Maybe they also changed the length of the bolts?

The dissimilar metals do still play a part, they will expand and contract differently and without proper clamping force they will blow out the gasket.
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1996 ZJ Green Laredo V8, 2.5" OME and Bilsteins, 33's, Holes drilled in the roof.
1998 ZJ Platinum Limited 5.9, Backyard parts fodder
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

Quote:
Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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