Stripped intake plenum bolt - Dodge Cummins Diesel Forum
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post #1 of 14 (permalink) Old 12-08-2019, 01:35 PM Thread Starter
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Stripped intake plenum bolt

I've managed to strip the rear passenger side bolt hole on my intake plenum, One of the four that holds the intake horn/grid heater down and it's causing a substantial boost leak. I'm not sure how to fix it. Previous owner put studs in and they have corroded enough that they won't move, except for this position, which I had to replace with a bolt a couple years ago. Basically the threads in the hole won't grab and they were probably already damaged when I Heman over tightened it, and now it's toast.

Are the threads in the actual head? the intake plenum itself? How do I fix this? Helicoil?


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post #2 of 14 (permalink) Old 12-08-2019, 02:02 PM Thread Starter
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Well I found the answer- the threads are in the head, and I did an awesome job of totally cracking the ear off. Sweet. Awesome.

Think the only fix option I have right now is getting a piece of long all thread, putting a bit on the bottom and top. F$&@ me.




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post #3 of 14 (permalink) Old 12-09-2019, 10:13 AM
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Why not replace the plenum cover?


one example of whats out there...

https://www.dieselpowerproducts.com/...e-cummins.aspx

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 428k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #4 of 14 (permalink) Old 12-09-2019, 11:33 AM Thread Starter
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Originally Posted by steve05ram360 View Post
Why not replace the plenum cover?


one example of whats out there...

https://www.dieselpowerproducts.com/...e-cummins.aspx
I thought about that, but as I discovered the threaded holes are actually in the cylinder head, which I broke. The "stud" I made with a nut on the bottom is working pretty well. The boost leak from the gap in the intake elbow and grid heater is gone. I had a little bit of a leak coming up through the nut on the stud, but some blue locktite on those threads appears to have fixed that as well. My other studs have nylock nuts on them, but I couldn't find those for non-metric bolts at the hardware store yesterday. Word of caution- do NOT over tighten your intake bolts!

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post #5 of 14 (permalink) Old 12-09-2019, 11:47 AM
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Ah, got it, yeah that sucks.

It sounds like the stud method is holding, hopefully it lasts & no more issues with it.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 428k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #6 of 14 (permalink) Old 12-09-2019, 11:51 AM Thread Starter
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Fingers crossed.

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post #7 of 14 (permalink) Old 12-09-2019, 04:14 PM
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Had that happen to me. RTV'ed the piss out of it and held 50psi for about a year till I burnt up that engine and fixed it the right way.
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post #8 of 14 (permalink) Old 12-09-2019, 04:33 PM
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Quote:
Originally Posted by Kmehr View Post
I thought about that, but as I discovered the threaded holes are actually in the cylinder head, which I broke. The "stud" I made with a nut on the bottom is working pretty well. The boost leak from the gap in the intake elbow and grid heater is gone. I had a little bit of a leak coming up through the nut on the stud, but some blue locktite on those threads appears to have fixed that as well. My other studs have nylock nuts on them, but I couldn't find those for non-metric bolts at the hardware store yesterday. Word of caution- do NOT over tighten your intake bolts!

Hope it works a long time for you
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post #9 of 14 (permalink) Old 12-09-2019, 07:18 PM Thread Starter
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Had that happen to me. RTV'ed the piss out of it and held 50psi for about a year till I burnt up that engine and fixed it the right way.


How would you even fix this short of milling the intake plenum off and getting an aftermarket one?


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post #10 of 14 (permalink) Old 12-10-2019, 12:00 PM
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Correct. LOL
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post #11 of 14 (permalink) Old 12-11-2019, 11:30 AM
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Quote:
Originally Posted by Kmehr View Post
How would you even fix this short of milling the intake plenum off and getting an aftermarket one?


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that's the only way, I don't even think you could reasonably weld it back if you wanted to.

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post #12 of 14 (permalink) Old 12-11-2019, 11:59 AM Thread Starter
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Yeah i don't see a feasible way to weld it.

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2005 QCSB NV5600, SouthBend OKHD, CFM+, Jake brake, Thuren 3in, Vulcan w/ CAT UHE 416-1225, CTS2, HPTuners by Optimal Welding, BBI stage 1, II bag of parts
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