I've been advised that the 5.9L engine can suffer a catastrofic failure of
the intake manifold gasket around 100K miles because when it fails it will
suck all the oil out of the engine in a very short time (only a few
minutes). It's apparently related to the intake manifold bolts stretching
and the guy at my dealer's parts department knew about it (don't know if
there was a TSB). Therefore, I am in the middle of replacing the gaskets
but found an unadressed step in the Dodge service manual.
The Dodge factory service manual fails to mention that in order to pull the
throttle body assembly I must either remove the fuel rails from the intake
manifold and set them aside or remove the fuel inlet line which requires a
special tool (I found the Snap-on part number in a different chapter of the
Which is the best way to perform this repair assuming I will keep the
vehicle for another 100K miles?
1) Buy the special tool to remove the fuel feed from the fuel rail.
2) Remove the fuel rails from the intake manifold and replace any O-rings
etc that may be required.