97 Fuel Solenoid Shutoff

[BSoldie]

I recently experienced a problem with the fuel shut off linkage in my 97 2500. After I shut the engine down, it would not restart with the key unless I manually pulled the shut off lever up by hand via the solenoid. Furthermore, the truck would then not shut down when I turned the key to the off position. I assumed the solenoid was bad, and since Dodge wanted $440 for a new one, I went to Cummins Northeast and got a whole solenoid kit for $261. 00. After installing the new kit ( replacement solenoid was almost twice the size, requiring the use of the include mounting bracket) the engine would still not start with the key unless I pushed the solenoid up with the shut off linkage connected while the key was in the "on" position. The truck would now shut down with the key. I liberally sprayed penetrating lubricant on the linkage to free it up before I installed the new solenoid. Then today, I tried starting the truck with the key after running it for about 1. 5 hrs. and it started as normal. What gives? Any insight is greatly appreciated

 

[illflem]

You probably didn't need to replace the solenoid, it is probably the most needlessly replaced item on a 12 valve. They are a very simple device and should last the life of the truck. Sounds like the solenoid relay is going. Can't remember the exact price something like $50 from the dealer $12 from Radio Shack.

 

[Joe G.]

Bad relay on the firewall that controls the fuel solenoid.

 

[Joseph Donnelly]

The bolt that clamps the + battery cable on the driver's side battery has a stud on its head, with various leads attached. One is the hot lead to the passenger side battery. Two are fusible links, one blue and one orange. The blue one goes to the fuel shutdown relay. This connector often becomes corroded or the wire gets corroded because of battery acid. If so, clip off the terminal and crimp on a new one.



The key to this diagnosis is the use of a cheap test light. Disconnect the fuel shutdown solenoid. There are three leads in the wiring harness--hot=start, ground, and hot=run. When the connection at the battery is poor, the test light will probably glow dimly when connectted to the start pin of the wiring harness.

 

[shendren]

fuel solenoid relay..... i keep an extra in the glove box. $20 from siemens.



on the firewall above the fuel filter. the relay towards the driver's side.

 

[BSoldie]

Originally posted by shendren

fuel solenoid relay..... i keep an extra in the glove box. $20 from siemens.



on the firewall above the fuel filter. the relay towards the driver's side.

Thanks to all who responded to my post! I certainly appreciate the insightful feedback and expertise offered to me. Since this is my first time using the discussion forums as a new member, I am happy to report that I will continue to subscribe to TDR for as long as I own a Cummins Dodge. And I suspect that will be for a long time! -BSoldie