Engine/Transmission (1994 - 1998) fuel shutoff solenoid

[Butch Brandt]

After only 199,000 miles the solenoid has quit. Are there any good choices besides $400. 00+ for a new one?

 

[redram]

1. Rebuild your starter contacts because that is probably the cause of the solenoid failure. You can find info by searching.



2. Parts are only $20 and can easily be installed with hand tools.



3. You could convert to a manual cable and eliminate the electric solenoid. Again, using the search feature you should beable to find info on this.



Good luck. Sounds like you got your money's worth out of this item at 200K miles.

 

[Joe G.]

When you post a question like this we need to know the year of your truck at least.



The first thing to know is that it is probably NOT the fuel solenoid. The most likely culpret is the fuel solenoid relay. There are two relays on the fire wall above the rear of the engine on the master cylinder side. The large one is the one you want to look at. What usually happens is that the contacts burn.



Anyway you need to do some trouble shooting before spending any money.



Search this forum for a LOT of info about finding the problem and fixing it.

 

[USMCBay]

This is what I did

I bought a $400 solenoid and while taking off the old figured out how to make my own shut off. (returned part).

I took a 1/8" cable and crimped an electrical terminal onto it. (If my memory serves me correct it was for a 1/4" stud. )

Anyhow I drilled a small hole level with the solenoid area through the firewall and pulled the cable through and into the dash (no hole drilled) right side of the steering wheel where the separation point is in the lower dash and upper.

Under the hood I rigged an L bracket to the shut off lever and attached a spring to keep it up.

With this setup you can start as usual but to shut down you just give alittle tug and put your money back in your pocket or somewhere else under your hood :-laf .

Or at the least this will get you back on the road. I just got used to it and cant find the logic in the $400 if this fix is doing the same job. (spray the cable with a rubberized coating to alleviate engine noise into your cab)

Anyone else... ... ... ... .

 

[Futures1]

You probably know about this ??

I recently bought my truck and am searching everything I can find to help me learn how to care for it and what to expect from it !!



I happened across this site last night and ordered a couple of those items which are claimed to help avoid the problem that you have Butch Brandt. Or at least extend it for a while ?? Looks like lot's of Cummins owners have had a similar situation. check it out:

http://www.fostertruck.com !!

Dick S.

 

[illflem]

Don't waste your money on the solenoid, they rarely fail. Replace the starter contacts and the relay, easy jobs. Get the parts here- http://www.fostertruck.com/dodge/default.htm -great prices and service.

 

[USMCBay]

SOLENOID

Wow, great site Illflem thanks. (again).

I will have to dig into the BOTTOM DRAWER of my tool box and revive the ole' thing.

I also have a brand new solenoid for a cummins but with a different bracket (was given to me by a heavy equip. mechanic). Maybe I can swap out plunger and contacts or change out the plug and rig a bracket.

 

[Joseph Donnelly]

The topic bar said fuel shutoff solenoid, not starter solenoid.



Check the blue fusible link wire at the driver's side battery, + terminal. Corrosion can interrupt circuit continuity and then the relay on the firewall won't work, and the fuel solenoid won't get juice for the pull-up mode. If you pull up the solenoid manually, it may still get power to remain up (engine run mode).

 

[redram]

Yep Joe You're right. Forgot about that fusible link blowing when my solenoid fried the wires due to the starter hanging up due to worn contacts. Sometimes it's hard to tell that the starter is even hanging up and continue to be powered due to the noise of the engine, windows and doors being closed, etc.



Dodge dealer wnated $18 for the link - but you can get one from an autoparts store for a couple of bucks, even included the terminal ends and shrink tubing.



Goog luck.

 

[HoleshotHolset]

Who has a shutdown solenoid boot kit?



Dad's boot fell apart in his hands the last time we played with the pump... .



Matt

 

[illflem]

Originally posted by HoleshotHolset

Who has a shutdown solenoid boot kit?

Any bike shop. Just use a short length of bicycle innertube with a couple of cable ties.



I suggested to Larry B that he find a source for the boot but he could only find them in large quantities. Cummins was selling the boot for $19 but the last time I tried they said the part number was no good, others who I gave the number to had the same problem.

 

[DKayser]

Testing?????

Is there abench terst for this solenoid? I had one replaced, and now wonder if it was bad or not. They replaced the relay too. This info is why I joined, to learn and save time, trouble,and cash. Also to know the job is done right the first time. Don.

 

[HoleshotHolset]

Bill: I told Dad about the inner tube thing, but he wanted a 'more OEM' solution.



I took the Hilljack approach - put on a PTO cable.



Matt

 

[illflem]

Don, replacing a still functioning solenoid is one of the dealer's favorite money makers.

Connect a 12 volt battery up to your solenoid, black is neg, positive to red will make it lift, light green will hold it. The lift circuit pulls a lot of juice, use at least 12 gauge wire.

 

[Joe G.]

The pull on wire on mine is white. Anyway, it's the big wire that is not black. The small wire is the hold wire.

 

[Scot]

Piers has a good price on the solenoid.