Engine/Transmission (1994 - 1998) fuel selonoid

[GAdams]

I have read most of the past posts on the fule selonoid and still have questions. Mine will not start on the first start of the day and on all other starts it acts normal. I push the plunger up and away we go. How do I lube it? and are there any other connections other than the wires leading to the three wire connector and the one battery connection? appreciate any advise.

 

[PKemp]

I had the same problem. Lubing it is a waste of time. Has the rubber boot around the plunger torn or deteriorated. If so you'll probably have to replace the solenoid. A new one directly from a cummins shop is much cheaper than a dealer and is a heavy duty model. Its easy to replace, takes about 30 minutes and the new one comes with a new mounting plate and all the screws.

If your having to push the plunger up and no one has messed with it before the solenoid is probably becomming too weak to do its job. They rarely go out of adjustment. They just get weak and eventually fail. If you wait too long to replace it I'd advise you to get a couple long tie straps and keep them in the glove box. At least then when it does fail you'll be able to "tie" it up and make it home, (I had to use a shoe lace). Remember though to take the strap off before you shut off the key so the plunger will drop and shut off the fuel or your engine "might" just keep running after the key is off. Tricky but it will get you home or to a shop. Start looking now... ... .

 

[JoeBioDiesel]

I've got a '96 too and have been having troubles with it starting intermittently. I checked the relay for the solenoid (it's the big one on the firewall right near the solenoid) there was lots of corrosion at the 12V power wire to the relay. I took it apart and resoldered some good wire to the connector. It started great for a couple of tries, then stopped starting at all. I took the relay apart and cleaned the contacts. They were pretty scorched. It's been starting fine ever since.

Good luck,

Joe

 

[illflem]

The solenoid is probably the most needlessly replaced part on a 12 valve and expensive too!

Unless the starter contacts have failed and fried the lift up coil the solenoid will last longer than your door hinges. There are no "weak" solenoids, either it works or it doesn't, the problem is coming from another source.

http://www.fostertruck.com/dodge/default.htm has the solutions for you.



Also read this thread about the boot https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=82320

 

[BGDUMMY]

When the key is turned on, but not cranking is the solenoid suppose to lift then?

I'm Trouble shooting a hard start in morning, but mine only raises when the engine trying to turn over and I'm wondering, if this is my problem,

 

[Jim Fulmer]

BG, the holding coil is energized when the key is on but the raising part of the coil gets it's power from the starter which won't happen till your try to start it!



Jim

 

[GAdams]

thanks for the tips on the fuel selonoid. I have ordered parts from Larry B and when they arrive I will get them installed. Thanks again

 

[LarryB]

GAdams

Got your order and it will go out tomorrow. You should have it Wed, Thur latest.



I have also found a source for the stock replacement solenoid boot but I don't have them yet. They are coming. Watch my site. The boot is actually patented because it is designed to retain the plunger in the solenoid. Hence the square shape instead of an accordian style. Unfortunately they aren't cheap and because of the patent I couldn't make them. They are far cheaper than replacing the entire solenoid though.

 

[BGDUMMY]

Thanks Jim for the info. & congrats on making the "700 club".

Larry B, keep us informed as to when you have them. A little piece of rubber could not be that bad, right? LOL