Engine/Transmission (1994 - 1998) Fuel Shutoff Solenoid problems

[surfbeetle]

This week the truck has been low on power so I changed the fuel filter, no change. Realized that there was no smoke with the low power so it wasn't a boost issue. Also finally realized that the power sometimes would come back after restarting the truck. So it had to be the fuel shutoff solenoid.



After testing it and finding that the rod could move up and the power returned, I took off the solenoid, disassembled it to clean it. A few years ago, I had put a new cover over it and cleaned it then. So this time when I took it apart, the threaded rod on the end popped loose from the plunger. The small internal spring came out along with the circle clip inside of the plunger. It looks like the clip and worn to the point that the threaded rod barely stays attached to the plunger.



My question: Is there a way to repair this or will I have to buy a new solenoid?



I did put it all back together and the truck started a couple of times with no issues.

 

[GAmes]

This is my "temporary" fix I made while on the road about 2 years ago. Another member donated his broken one to me and I have an identical plunger in my spare parts box.

 

[hsmith]

Gary has "been there-done that".

 

[MLee]

There is a measurement for the rod, I don't know what it is, for a full throw of the plunger. Clean is the answer.

 

[surfbeetle]

Thanks everyone, I didn't even think of that quick fix. I will do that for a temp fix. I looked on Geno's and they have a solenoid with a 2 1/2" bolt spread. I have to measure so I can order or not order the bracket with the solenoid.