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1994.5 - 1997 7.3L Power Stroke Diesel  

94.5 intake plenum reseal

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Old Mar 30, 2025 | 05:43 PM
  #1  
nomad221's Avatar
nomad221
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94.5 intake plenum reseal

Hey guys. I haven't posted in a loooong time. Fully appreciate All of the info and wisdom of the members here over the years.

For anyone who is new with an OBS 7.3, this is IMHO the #1 site.

It's time to reseal the plenums. I've searched and searched a bunch and getting conflicting answers regarding having to remove the stock turbo.

I haven't started yet and want to plan for what's needed to get the job done.

Does a 94.5 turbo have to be removed ?

Thanks all
 
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Old Mar 31, 2025 | 10:53 AM
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I had to pull the turbo to do mine, there wasn't enough room to remove the lower rear bolt on the drivers side.

Also be prepared for the passenger front lower bolt. On the newer ones (95/96 ) the bolt hole is slotted so the plenum can be slid out. on the 94 trucks its a hole like all the other ones. I very carefully cut the plenum with a dremel so it could be slid out without removing the hpop reservoir

Have fun and take your time
 
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Old Mar 31, 2025 | 11:17 AM
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I could not recall, sorry. I do know I used TA31? sealant for them. May as well upgrade the boots and inserts while apart.
 
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Old May 5, 2025 | 06:53 PM
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Thanks gents. Will one 5oz tube of ta31 be enough to seal the plenums and have some leftover for the hpop reservoir ?
 
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Old May 29, 2025 | 03:13 PM
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Bump with a question thanks
 
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Old May 30, 2025 | 08:31 AM
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Originally Posted by nomad221
Thanks gents. Will one 5oz tube of ta31 be enough to seal the plenums and have some leftover for the hpop reservoir ?

Without a doubt, you dont need much for the plenums. just a small 1/16 bead is good enough
 
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Old May 30, 2025 | 02:25 PM
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Thanks !
 
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