Full PDF Instructions can be downloaded here: https://www.riffraffdiesel.com/content/RESOURCES/Riffraff_PDF_Plenum_Inserts_Instructions.pdf

Product Links:

1994- Early 1999: https://www.riffraffdiesel.com/rdp-plenum-reinforcing-inserts-94-early-99/

1999.5-2003: https://www.riffraffdiesel.com/rdp-plenum-reinforcing-inserts-99-5-03/

IMPORTANT: Before starting installation, please be sure that all items supplied with the kit are accounted for. 

Parts Required: Riffraff Diesel Plenum Reinforcing Inserts

Tools Required:

1. Standard pliers
2. Metric and SAE sockets and ratchets
3. Large and long flat-blade screwdriver
4. Hammer
5. Block of wood (2x4, approx 5-6” long) or a soft, non-marring substitute

Optional Tools/Supplies:

1. Degreaser
2. Stainless Steel T-bolt replacement clamps

SUGGESTION: BE PREPARED TO TIGHTEN, OR AT LEAST CHECK THE TIGHTNESS OF ALL HOSE/BOOT CLAMPS WHILE YOU’RE UNDER THE HOOD, ESPECIALLY THE CLAMP AROUND THE DOWNPIPE CONNECTION ON THE DISCHARGE SIDE OF THE TURBO EXHAUST HOUSING.

1. If present, remove Powerstroke cover (13mm deep-well socket).

2. If present, disconnect these items from the intake spider (compressor manifold):

• Black rubber hose to MAP sensor
• Exhaust pressure regulator
• Red tube to wastegate actuator
• Intake manifold pressure sensor connector 

3. As indicated in fig. 2, loosen the following clamps:

• Hot intercooler tube boot (upper right)
• Cold intercooler tube boot (upper left)
• Manifold connection to turbo

4. Loosen the four clamps on the two boots at the bottom of the spider where they connect to the intake plenums.

5. Remove the spider. It will take a little bit of wrestling, but be careful to not tear a boot in the process if you have stock boots. 

6. Take the plenum boots off (the ones from the bottom of the spider) and clean them out with degreaser if they have oily residue in them.

7. To install the new inserts, place the tapered end into the plenum opening, and then lay the block of wood across the top and tap the inserts all the way in until the top lip of the insert is flush with the top edge of the plenum inlet tube. This top lip prevents the inserts from going too far. (fig. 3, fig. 4)

NOTE: Make sure that the block of wood is completely flat across the top of the insert, and tap it evenly so the insert does not go in crooked or cocked to one side. Also, while tapping in the insert, it will sound sort of like tapping on an empty soda can. Once the insert is completely seated, the sound of your tapping will change noticeably and will become much more solid sounding.

8. Reverse steps 1-6, making sure to get all your clamps tight. T-bolt clamps are suggested since you are now able to clamp aggressively on the plenums.

SUGGESTION: Some people like to use some hair spray on the inside of the boots before clamping them down as a very light adhesive to minimize potential boost leaks. Hairspray is not necessary if you are running aramid boots from Riffraff Diesel Performance.

9. Make sure that you remove all your tools, rags, etc. from under the hood.

10. Double check your connections to make sure all sensors and clamps are securely connected.

Instructions and pictures provided by Clay, Pete (250_), and the whole FTE crew.

***Disclaimer: The information provided on this blog is for informational purposes only. We share our knowledge and experience, but we are not liable for any damages, injuries, or losses that may occur as a result of using this information. Situations are rarely cut and dry in the automotive world. Your situation will likely be somewhat different than what we describe here.  Use your best judgment and always consult a qualified professional for automotive repairs and modifications. Your safety is your responsibility.