hughes plenum upgrade - JeepForum.com
 
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post #1 of 13 Old 07-29-2018, 06:18 PM Thread Starter
brad88yj
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hughes plenum upgrade

Most the threads on here about the hughes plenum are pretty old. I'm in need of fixing intake leak and just wondering if theres anything new out there or tips pros cons etc they want to share?

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post #2 of 13 Old 07-29-2018, 07:50 PM
HighLonesome
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If I didn't have EGR, I'd weld the plate to the intake and forget about leaks forever. Well I'd have it welded by a good TIG person.


The EGR passages inside the intake need to be cleaned every now and then on the early ZJs.
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post #3 of 13 Old 07-30-2018, 03:19 PM
kg6mov
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A few people have had good luck just doing new gaskets and different hardware, that’s actually what I’m running now in my 5.9. There’s some speculation that the fatory hardware is actually too long and prevents proper clamping force on the plate and gasket.

The hughes kit is pretty much the gold standard, but there are also people selling the same thing on ebay for a lot less money than hughes wants.

Here's my thread on the process. https://www.jeepforum.com/forum/f13/k...l#post19732865

And an addendum: https://www.jeepforum.com/forum/f13/n...l#post23796778


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1984 F250, 460 BB, T19, work truck/future tow pig
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post #4 of 13 Old 07-30-2018, 05:40 PM
jrcromwell
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I have run a Hugh's plate with the FEL-PRO gasket since 2015 on my Niner. I am happy with it.

If you can get that plate for a lot less then heck yea. Whatever you do I would not use an inferior gasket set.
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post #5 of 13 Old 07-31-2018, 10:15 AM
chetzar
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I did not have much luck with the Fel-Pro gasket, mine started leaking again within a year.

1993 ZJ Limited - 4.0
1994 ZJ Limited 5.2
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post #6 of 13 Old 07-31-2018, 10:21 AM
UTNiner
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I just did the repair with the Hughes stuff. Nice quality looking parts, pretty straight forward repair. Haven't been able to check for leaks yet as I'm am repairing other things as I go back together

Platinum 5.9, 3.5" lift, 231 w/SYE 265/75/16 on Stock Wheels
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post #7 of 13 Old 07-31-2018, 02:38 PM
Timo_90xj
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I did the hughes plate & fel-pro gasket about three years ago. No issues so far, but my Jeep has been sitting in the garage for the past 15 months.


Hughes plate is nice, but it's really just a piece of 1/4" aluminum cut to shape and drilled. If you can a similar plate somewhere else cheaper, go for it. As long as it's straight and has the right shape & hoes where they should be, there really isn't anything that can go wrong with it..

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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post #8 of 13 Old 08-02-2018, 09:11 AM
Boone96ZJ
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I upgraded to the Fel Pro Hughes kit in June 2017. I followed the directions to a T. It still leaked a few weeks later. I checked the intake for straightness along with the new plenum. They were fine. I emailed Hughes and they sent me another gasket set no problem. No leaking since then, except an extremely small one from back corner of passenger valve cover.

96 5.2 242 3" 32x11.5
https://www.jeepforum.com/forum/f13/1996-grand-cherokee-laredo-5-2-a-2570290/
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post #9 of 13 Old 08-02-2018, 03:05 PM
RWC
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The FelPro gasket has rubber ridges impregnated, which I think work better with the steel since it flexes a little at each bolt head. The first one I did also leaked at one of the bolts, and I suspect it was due to a lack of flex since the aluminum plate is rigid. AutoZone warrantied the gasket (I bought the eBay plate and bought gaskets locally), and when I did the job again I sealed it up with a very light layer of Permatex Ultra Grey on all surfaces. That didn't leak. When I went to do my wife's 5.9L a couple months later, I also did the light layer of Ultra Grey with the FelPro gaskets and it also didn't leak. Both of these ZJs have been running with these kits for . . . 5 years now, IIRC.
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post #10 of 13 Old 08-03-2018, 05:45 AM Thread Starter
brad88yj
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Quote:
Originally Posted by kg6mov View Post
A few people have had good luck just doing new gaskets and different hardware, thatís actually what Iím running now in my 5.9. Thereís some speculation that the fatory hardware is actually too long and prevents proper clamping force on the plate and gasket.

The hughes kit is pretty much the gold standard, but there are also people selling the same thing on ebay for a lot less money than hughes wants.

Here's my thread on the process. https://www.jeepforum.com/forum/f13/...l#post19732865

And an addendum: https://www.jeepforum.com/forum/f13/...l#post23796778
I liked your write up. I thik I'm going to get the new aluminum bottom. I couldnt find any other then hughes however, Do you know what you used to find the off brands?
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post #11 of 13 Old 08-03-2018, 08:53 AM
Boone96ZJ
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simple ebay search for 5.2 plenum

https://www.ebay.com/itm/DODGE-360-M...sid=m570.l1313

96 5.2 242 3" 32x11.5
https://www.jeepforum.com/forum/f13/1996-grand-cherokee-laredo-5-2-a-2570290/
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post #12 of 13 Old 08-03-2018, 01:05 PM
kg6mov
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Yup, there’s always some shop on ebay that’s selling them, just gotta search around. The ram, dakota, and durango guys have the same problems we do.


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1984 F250, 460 BB, T19, work truck/future tow pig
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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post #13 of 13 Old 08-04-2018, 07:41 PM
Billyjoebob007
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Quote:
Originally Posted by chetzar View Post
I did not have much luck with the Fel-Pro gasket, mine started leaking again within a year.
I used eldebrock gaskets about 5 years ago when i did mine and no leaks yet.
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