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General Dakota Board
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ZoSo
Dodge Dakota
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3/07/2006
09:41:46
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 Subject: Hughes Engines
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Message:
For anyone who has bought the Hughes Engines intake plenum cover kit (#7714 for the 5.2/5.9) how many of you also bought the 3205A or 3205B (Fel-Pro set with torque-to-yield bolts)?
Was it worth purchasing those bolts or did you reuse the stock bolts without any problems?
Thanks,
ZoSo
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Rick
Dodge Dakota
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3/07/2006
10:37:40
| RE: Hughes Engines
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I bought the Hughes aluminum plenum cover and the gasket/bolts set. The TTY bolts stretch when you first put them in, so they can't be re-used. Follow the torque specs carefully when you do the repair. I'm not so sure about the bolts that hold the manifold assembly to the crankcase. I used new ones there, too, just to be safe.
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ZoSo
Dodge Dakota
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3/07/2006
11:00:32
| RE: Hughes Engines
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Rick,
If you dont mind my asking what was the outcome of your fix? How long did it take? Any advice for a first timer?
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Rick
Dodge Dakota
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3/08/2006
12:51:53
| RE: Hughes Engines
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I was also a first timer. I read all the posts on this board and others that I could find regarding intake manifolds, and I bought everything I would need ahead of time (bolts, gaskets, thread locker, gasket maker, etc.). I had with me the instructions for installing the M1 manifold (for the disassembly), the Haynes manual with appropriate pages marked, and the TSBs for the manifold repair and the spark plug rerouting (to eliminate induction effects). I did it all myself, but having a friend on hand for emergency trips to the auto parts store is recommended!
On a Saturday, I got started disassembling the engine around 8-9 am. By noon, I had the manifold off. By 12:30, I had cleaned it throughly and installed the aluminum plate. It took about another 3-4 hours to get it all back together, including an oil change. Thank God no bolts broke.
I broke the brittle, plastic vaccuum port thing during the disassembly; turns out it's a dealer only part, so I got a short piece of tubing from a local auto parts store, yadda yadda.
Since my engine had been burning oil for who knows how long, the following day I put in new spark plugs.
It ran like a new truck! It was awesome. That lasted about four weeks, then it started missing at idle every now and then, but not nearly as bad as it had been before the repair. I put half a can of SeaFoam through the throttle body, and it ran good again for a few days. I think my spark plugs got fouled up by residual gunk in the cylinders which had been burning oil before the repair. Next time I change the oil, I'm going to use some crankcase cleaner. I'll also put some fuel system cleaner into the gas tank at that time. At least it doesn't miss during driving.
Other misc advice:
It was difficult to maneuver the fixed intake manifold back into position on the new gaskets while fitting the coolant bypass hose. The intake manifold isn't heavy if you just pick it straight up, but holding it outward at arms length for half a minute or so is tough.
I found my knuckle driver to be handy for removing loosened bolts and starting them back.
Label everything you can during disassembly, and take photographs every now and then just in case. I referred back to my photos to get the throttle body linkage reinstalled correctly.
I worked as quickly and carefully as possible once I got started. I didn't want to risk forgetting which pieces went where. I even skipped lunch to this end - and rewarded myself that evening with a giant dinner.
The only other advice I have is not to do this in your driveway in the middle of a winter month, which is what I did. As I recall, military studies in the arctic show that people can learn to tolerate working in cold better, but they never feel less pain from it.
Good luck!
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Rick
Dodge Dakota
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3/10/2006
11:16:08
| RE: Hughes Engines
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Message:
Meant to add --
My fuel economy shot way up after I fixed the belly pan gasket. If the best Dakota mileage is around 14 mpg, I shudder to think what I was getting before.
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ZoSo
Dodge Dakota
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3/10/2006
12:30:18
| RE: Hughes Engines
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My fuel mpg is right around 14.9 according to the overhead computer. Now knowing its always a little off I would say at an average of 14.4 mpg.
ZoSo
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