Engine/Transmission (1994 - 1998) Fuel Shutoff Solenoid

[MAllen]

My fuel shutoff solenoid is messing up on me. The truck fires up by cranking it over a little longer, or by going under the hood and lifting the plunger all the way up. What is the easiest fix to get it going? Thanks

 

[hereismylife]

The only way I know is you have to replace it with a new one. Also you might be losing power some where but it is probably ready for a replacement.

 

[KLockliear]

Before you change the solenoid, make sure the pull relay is doing it's job. If the relay doesn't send power to the solenoid, the solenoid won't pull. There is a separate relay for the pull and the hold actions of the solenoid.

 

[WilsonF]

I have read here and other diesel sites that the shaft on the solenoid needs to be cleaned and lubed from time to time. Then check the fusible link to the solenoid then the relay. You may have to change the solenoid but suspect it last, spendy little bugger.
Floyd

 

[GAmes]

It takes less than an hour to remove it, clean up the plunger and bore and reinstall it. The boot deteriorates and pieces sometimes get caught up in there as well. I discarded mine 300k miles ago. I use a shotgun bore brush to clean the bore of the solenoid, 500 grit sandpaper on the plunger, a little dry lube and reassemble. The only tricky part is removing the small wire clip that holds the arm to the fuel lever.



FWIW, I still have the original solenoid and relay.

 

[95REDRAM]

Ditto on what GAmes said. It's probably the boot making it hang up. I changed mine to a cable because the plunger finally wore out and literally fell out of the bore of the solenoid. Electrically it was fine but mechanically it was worn out. I really like the cable.

 

[MAllen]

It turned out the original boot had disenegrated & got wedged in the spring making it hard to move. I cleaned all of that off & it works fine now. I'm ordering a new boot to keep it protected & I should be good for a while longer. Thanks for the help.