Engine/Transmission (1994 - 1998) Fuel shut-off solenoid fell apart! Truck wouldn't shut off.

[Jeff]

Tore into my fuel shut off solenoid today... it is working (pulls large plunger up when I hit the key) , but the bottom part of the barrel which contains the adjustment nut and bolt (looks like it's threaded up into the silver plunger) fell completely out and was hanging upside down on the linkage that shuts the truck off. I hate to buy a new solenoid if mine is working, but I'm not sure they sell a rebuild kit for the guts inside the barrel. What I am saying is that I have the solenoid, the silver barrel and the banjo fitting (adjustment nut/bolt) all are separated. If that is supposed to be threaded up in there... the threads are completely gone. There is a little spring and retaining clip up inside that large silver plunger. Let me know if I have any options. Thanks, Jeff in Ohio

 

[CarlJensen]

Link below is for good PTO cables. Go to "Truck Equipment" on site. Replace the solenoid with a PTO cable to control fuel arm. No more solenoid problems and, if well hidden, a theft deterrent.



http://www.awdirect.com/

 

[NBowlin]

I used the part numbers from charland(Sp) and got my cable from international.

made for our pump and all. put it in tonight and its pretty slick, beats opening the hood to undo a wire and a bungy cord

 

[LarryB]

Jeff



It's probably just the boot is rotted off and the plunger fell out. The boot is the only thing that holds the plunger in. More info on my site www.fostertruck.com/dodge Or give me a call Monday AM after 9:00 PST and Ill answer any further questions. 253-272-1444

Larry

 

[Howard Durand]

Get a new boot for it from Larry.

Mine was coming apart but neither Cummins or Dodge would help. Said that it is not a separate part.

I gooped mine up with some liquid electrical tape and it is still working fine.

Some folks have used a short piece of bicycle inner tube to make a replacement.

 

[PA95CTD]

Soleniod boot

I just put a new boot on my solenoid and it's toast, if anyone wants it i'll sell it for half price. I got it from Larry Bs, it's brand new. PM me if anyones interested.



Marc

 

[Jeff]

Rubber boot.

PA95CTD : PM sent.

 

[ABorchard]

I just put a new boot on my solenoid and it's toast, if anyone wants it i'll sell it for half price. I got it from Larry Bs, it's brand new. PM me if anyones interested.



Marc

Probably too late but are you sure it's toast? Very rare for one to fail unless the starter sticks and the solenoid overheats. You can definitely smell it, some even catch on fire. Most times the problem is just wiring or the relay. Sometimes replacing the solinoid you think you've fixed the problem when all you really did was move around a wire that had a bad connection.

 

[edmeyers]

my banjo thingy will not styay in the silver plunger either i just installed LarryB's boot hoping that it would keep it all together but it will not has anyone found a way to make the adjustment bolt stay in the plunger after it has gotten to the point that it will not hold.

 

[GAmes]

The boot isn't needed to hold it all together, mine rotted away many miles ago. Every now and then (when it starts sticking) I pull the assy off and clean the plunger and bore. If the rod is broken off the plunger I'd venture you'll have to bite the bullet and get a new one. I've heard LarryB has a good price on them.

 

[AMink]

I believe that you have to install it while holding the plunger in. The connections are what really hold it together. Even the boot may allow the plunger to "fall out". I had to do mine a while back. Seems like the bottom of the rod had a pin and cotter pin holding it on, the top was in the solenoid itself.

 

[GAmes]

Here's what the assy looks like, minus the boot. It looks to me like a good welder might be able to repair the plunger if the rod is broken away from it.