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Darrell Dubre
Dodge Dakota
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11/23/2009
16:53:21
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 Subject: 5.9 INTAKE GASKET REPLACEMENT
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hello
Truck is using one quart every 800-1000 miles.
I suspect it is intake gasket leaking. I had same problem on my wifes 1999 5.9 Durango.
Dealer paid half after I threw a fit. It had just went out of warr. I am not as lucky this time. I am going to repair myself. Can anyone give me advise and how much $ and time required.
Why has Chrysler not corrected this simple problem?
Thanks for any advise out there.
Darrell
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ehhhh
Dodge Dakota
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11/23/2009
21:40:19
|  RE: 5.9 INTAKE GASKET REPLACEMENT
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"Why has Chrysler not corrected this simple problem?"
They have corrected the problem,
They no longer make the 3.9's - 5.2's - 5.9's
Problem solved!
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dakownr
Dodge Dakota
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11/26/2009
03:30:41
| RE: 5.9 INTAKE GASKET REPLACEMENT
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Before you undertake this project, make sure that it is indeed the intake manifold plenum gasket that needs replaced. With the air cleaner assembly (and engine) off, manually open the throttle fully so that you can take a flashlight and peek down into the intake manifold and see the bottom of it. If you see some oil at the bottom, then it is the plenum gasket leaking.
A set of intake manifold gaskets will run you anywhere from $20 (advance auto and the like) to $30 (summit, etc). I would also recommend picking up a pair of valve cover gaskets, as you may have to remove a valve cover to get the intake manifold off. The amount of time it takes varies greatly depending on your mechanical skills, experience, etc. I would give yourself AT LEAST 6-7 hours if you've never done anything like this before. As you're taking apart the upper part of the engine, place your bolts in seperate zip-lock bags and label them so you don't lose them and can more easily remember what bolt goes where. When you place the front and rear manifold gaskets on (boot and hook shapes), place a dab of red RTV sealant on either end of each gasket to seal them at the corners and also keep them in place as you put the manifold back on. DO NOT try to remove the a/c hoses from the compressor- simply unbolt it and place it out of the way. If you need anymore help, just ask.
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Darrell D
Dodge Dakota
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11/30/2009
09:11:19
| RE: 5.9 INTAKE GASKET REPLACEMENT
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Thank you so much for your reply. I am an Industrial Refrigeration Mechanic by trade, and a Mopar gearhead from birth. I have learned over the years it pays to seek advice in advance to be productive with time and to avoid costly mistakes. There are always pointers and easier ways of doing things. Thanks for the advice.
I will check for oil in bottom of intake.
Darrell
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dakownr
Dodge Dakota
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11/30/2009
20:14:03
| RE: 5.9 INTAKE GASKET REPLACEMENT
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No problem. I agree that it is a good idea to ask questions; saves time, money, and headache. I also forgot to mention that as you're unplugging the wiring harness from misc. things, label all of them with masking tape and a sharpie. It is nearly impossible to plug things in wrong (everything has its own unique plug shape), but it will make assembling the engine go faster. Good luck and let us know how it goes.
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MC
Dodge Dakota
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12/01/2009
22:26:09
| RE: 5.9 INTAKE GASKET REPLACEMENT
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As above take your time and label your bolts and yes do not disconnect AC but put whole compressor off to side. Get a inch/lbs torque wrench for the job. The manifold replacement has 12 bolts that have a torque sequence that needs to be followed. Think about getting the Hughes plenum plate that is thick aluminum and designed better than the stock one. Any questions during the swap e-mail me at m.colantuoni@hotmail.com I have done these many times already.
Mike,
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jason j
Dodge Dakota
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8/12/2014
18:34:50
| RE: 5.9 INTAKE GASKET REPLACEMENT
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Just bought a 2000 dodge ram with this bugger needing to be done.. I plan to only own it for 75k-100k before selling it.. will just replacing the gasket get me that far. basicly I don't tow, don't go off road. don't go over 65.. so how many miles will I get on stock plenum?
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