Notices
1999 - 2003 7.3L Power Stroke Diesel  
Sponsored by:
Sponsored by: DP Tuner

Plenum leak between engine block and intake

Thread Tools
 
Search this Thread
 
Old Aug 28, 2019 | 10:42 AM
  #46  
Dan V's Avatar
Dan V
Lead Driver
Photogenic
Photoriffic
Shutterbug
Joined: Jun 2013
Posts: 5,647
Likes: 891
From: north of Minneapolis, MN
The taper is 82degrees. The rest of it just has to be figured out. As to the material, I'd look at 303 or I do have some 17-4 laying around.
 
Reply
Old Aug 28, 2019 | 11:07 AM
  #47  
slowsure's Avatar
slowsure
Tuned
5 Year Member
Joined: Dec 2016
Posts: 260
Likes: 6
From: Southern Middle TN
Could you take a coupling nut (long nut with threads thru all) and turn the 82° on the leading edge to match the plenum?
The stud would extend past the other end of the coupling nut and give you the needed stud.
If the coupling nut was long enough you might be able to make two nuts from one coupling nut by turning both ends and then cutting in the middle?
Just a thought.
 
Reply
Old Aug 28, 2019 | 11:19 AM
  #48  
Dan V's Avatar
Dan V
Lead Driver
Photogenic
Photoriffic
Shutterbug
Joined: Jun 2013
Posts: 5,647
Likes: 891
From: north of Minneapolis, MN
Coupling nut? Sure you could do that.

I'll have to look what I have in hex material....not much I recall.
 
Reply
Old Aug 28, 2019 | 11:29 AM
  #49  
Markus Luukko's Avatar
Markus Luukko
More Turbo
5 Year Member
Photogenic
Photoriffic
Joined: Feb 2018
Posts: 504
Likes: 24
From: CT
On McMaster, all I can find is 90 and 100* bolt heads nothing in 82* like UNC thread FHS.
The thread is M6-1.0
Can we confirm which it is?
 
Reply
Old Aug 28, 2019 | 11:39 AM
  #50  
slowsure's Avatar
slowsure
Tuned
5 Year Member
Joined: Dec 2016
Posts: 260
Likes: 6
From: Southern Middle TN
8mm Coupling Nuts
AmazonLinkage AmazonLinkage
 
Reply
Old Aug 28, 2019 | 12:50 PM
  #51  
Dan V's Avatar
Dan V
Lead Driver
Photogenic
Photoriffic
Shutterbug
Joined: Jun 2013
Posts: 5,647
Likes: 891
From: north of Minneapolis, MN
Looks like the metric flat heads are 90 degree. You can figure 1.5 the diameter for the required thread engagement, plus the thickness of what you are holding down.

M6?....that seems small to me, but then again, it's been a long time since I've been that far in to the valley.
 
Reply
Old Aug 28, 2019 | 12:57 PM
  #52  
Markus Luukko's Avatar
Markus Luukko
More Turbo
5 Year Member
Photogenic
Photoriffic
Joined: Feb 2018
Posts: 504
Likes: 24
From: CT
Originally Posted by Dan V
Looks like the metric flat heads are 90 degree. You can figure 1.5 the diameter for the required thread engagement, plus the thickness of what you are holding down.

M6?....that seems small to me, but then again, it's been a long time since I've been that far in to the valley.
Thats what I thought but that’s what I found online, all we need to know is the bolt size cause all FHS in one bolt size use the same head.
 
Reply
Old Aug 28, 2019 | 02:06 PM
  #53  
Ridedan2's Avatar
Ridedan2
More Turbo
Joined: Jun 2014
Posts: 734
Likes: 37
From: Schenectady
I'm not sure I am following this correctly or if I am missing something, however the tapered (3) washers came in my kit from Riffraff that I just installed. I used the bolts that came with the kit. You can buy studs, Put the tapered washer and nut on and you now have a stud.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Ford Truck Tragedies

 Joe Kucinski
story-1

AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

 Brett Foote
story-2

Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

 Michael S. Palmer
story-3

Ford's 2001 Explorer Sportsman Concept Looks For a New Home

 Verdad Gallardo
story-4

10 Best Ford Truck Engines We Miss the Most!

 Joe Kucinski
story-5

2026 Shelby F-150 Off-Road: Better Than a Raptor R?

 Brett Foote
story-6

2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

 Michael S. Palmer
story-7

10 Most Surprising 2026 Ford Truck Features!

 Joe Kucinski
story-8

Top 10 Ford Trucks Coming to Mecum Indy 2026

 Brett Foote
story-9

5 Best / 5 Worst Ford Truck Wheels of All Time

 Joe Kucinski
Old Aug 28, 2019 | 02:13 PM
  #54  
slowsure's Avatar
slowsure
Tuned
5 Year Member
Joined: Dec 2016
Posts: 260
Likes: 6
From: Southern Middle TN
Originally Posted by ExPACamper
I forgot to add a couple things.

1. The GPCM (Excursions only) mounting bracket needed studs, too. Otherwise it would have been directly against the plenum. If ever removing the bracket...say to service the HPOP fitting on the head side for example...you would have to remove the bolts that hold the plenum seal.

Here's a pic of that from the RRD install instructions (I haven't checked, but Clay said he was going to update them to remove this step as the kits don't have the parts any more)




2. I used double-nuts to make my threads into studs (jam nuts). So on my studs, the order goes Head, Plenum, tapered washer, washer, two opposing nuts (so I can tighten the stud using the top nut without holding the threads = good and solid with a fixed length of stud into the head), mounting bracket of whatever, washer, nut.

I hope this makes better sense.

Bottom line, once I put the intake plenums on, I am not planning on ever removing their sealing bolts. It's likely I'll have to remove AIH solenoid or GPCM bracket at some point. (I think I am going to remove AIH solenoid altogether soon).

Sure, it was a royal PIA and unwelcomed surprise while attempting to reassemble, but this is why we share our builds with so many pics. I benefit constantly from the experiences of those who have gone before and been so kind as to document and share their ups and downs.

Every once in a while it even leads to improvements in the products our vendors carry, too
This post quotes Riff Raff Diesel install instructions. It says M8x1.25 hardware. So I assumed M8. Unless it changed somewhere along the line.
Yes, McMetric Flatheads are 90°. I missed that in my earlier post about coupling nuts.
 
Reply
Old Aug 28, 2019 | 02:16 PM
  #55  
Ridedan2's Avatar
Ridedan2
More Turbo
Joined: Jun 2014
Posts: 734
Likes: 37
From: Schenectady
Yes they are 8, 1.25. I just checked.
 
Reply
Old Aug 28, 2019 | 02:28 PM
  #56  
Markus Luukko's Avatar
Markus Luukko
More Turbo
5 Year Member
Photogenic
Photoriffic
Joined: Feb 2018
Posts: 504
Likes: 24
From: CT

This is what I got for dimensions on the tapered washer aka the head of a m8-1.25 FHS

EDIT:
Upon further investigation, the length of the washer will need to be shorter to make the clearance 9mm hole
 
Reply
Old Aug 28, 2019 | 03:20 PM
  #57  
Dan V's Avatar
Dan V
Lead Driver
Photogenic
Photoriffic
Shutterbug
Joined: Jun 2013
Posts: 5,647
Likes: 891
From: north of Minneapolis, MN
I make things like this every day. This order is qty. 4.

12L14 material, 3/8-16 2A thread. The shoulder is .499 -.001

I'll draw something up tomorrow.
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
Ford-F100
1973 - 1979 F-100 & Larger F-Series Trucks
11
Jan 12, 2011 10:02 AM
Fordby4
1973 - 1979 F-100 & Larger F-Series Trucks
12
Aug 26, 2010 05:28 PM
wresleu
1983 - 2012 Ranger & B-Series
3
Mar 4, 2005 09:05 PM
dr worm
Explorer, Sport Trac, Mountaineer & Aviator
1
Nov 1, 2004 10:26 PM
76_F150_390
Oil & Lubrication
10
Dec 28, 2002 09:26 PM




All times are GMT -5. The time now is 12:59 AM.

story-0
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE
story-1
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

And it might be even better than that.

By Brett Foote | 2026-05-18 19:26:42


VIEW MORE
story-2
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

Slideshow: Does lowering an F-150 Lobo RUIN the ride quality?

By Michael S. Palmer | 2026-05-18 19:20:37


VIEW MORE
story-3
Ford's 2001 Explorer Sportsman Concept Looks For a New Home

Slideshow: Ford's bizarre fishing-themed Explorer concept has resurfaced after spending decades largely forgotten.

By Verdad Gallardo | 2026-05-12 18:07:46


VIEW MORE
story-4
10 Best Ford Truck Engines We Miss the Most!

Slideshow: The 10 best Ford truck engines we miss the most.

By Joe Kucinski | 2026-05-12 13:09:47


VIEW MORE
story-5
2026 Shelby F-150 Off-Road: Better Than a Raptor R?

Slideshow: first look at the 810 hp 2026 Shelby F-150 Off-Road!

By Brett Foote | 2026-05-12 12:50:07


VIEW MORE
story-6
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

Slideshow: Everything You Need to Know about the 2027 Super Duty Carhartt Package!

By Michael S. Palmer | 2026-05-07 17:51:06


VIEW MORE
story-7
10 Most Surprising 2026 Ford Truck Features!

Slideshow: 10 most surprising Ford truck options/features in 2026.

By Joe Kucinski | 2026-05-05 11:17:22


VIEW MORE
story-8
Top 10 Ford Trucks Coming to Mecum Indy 2026

Slideshow: Here are the top 10 Fords coming to Mecum Indy 2026.

By Brett Foote | 2026-05-04 13:49:49


VIEW MORE
story-9
5 Best / 5 Worst Ford Truck Wheels of All Time

Slideshow: The 5 best and 5 worst Ford truck wheels of all time

By Joe Kucinski | 2026-04-29 16:49:01


VIEW MORE