fuel solenoid removal

[DThibault]

I drove the truck this morning and shut it off in the driveway, went to go to the barn and no start. I checked the primary lift pump, changed the fuel filter and I guess its the fuel solenoid. What is the trick to getting it off. IS there a special tool or does one make one out of a 15/16 plus sized wrench. Any ideas or tricks welcome. Thanks

 

[Greenleaf]

Break off/cut off the bracket that sticks up beyond the top of the hi pressure head. Remove the throttle assy out of the way and use a 15/16 open end. Some I have found to be a bit smaller that a 15/16 wrench. Which case I used a hammer and chisel. No joke.



clean the area around that solenoid reall y well prior to removal. , There is an O ring that will likely stick in the (hole). The rubber plunger will also. Pull it up/out with your fingers.

 

[sdstriper]

It's another "not real easy one". 24mm is what is called for. I think I removed the linkage bracket and linkage, can't remember for sure. I have to take my hat off to the folks who do this on the road. I do remember this was another "swearing event"! I never did get the thing very tight after getting it back on the pump.



Here's a cheap replacement, I got two, one for the glove compartment and I can't wait to have to replace it on the road...



importedcarparts.com



SKU # D2004-61881 Injection pump solenoid ($37. 91 delivered)

 

[bopplumb]

My solenoid went out on mine last fall of all places"The transmission Shop" had truck towed to a diesel shop and they replaced it for me. $260. 00 When it rains it pours. I know were it is and what to do next time.

 

[Bob4x4]

If I had a first gen cutting the top of that bracket off would be done before it left the driveway!Pulling out the plunger on the road is then possible and no parts needed to drive it home



Bob

 

[btoscano]

I ground down one side of a 15/16" crow foot.



A hammer and chisel will also work.



Brian

 

[DThibault]

Whew, what a job. Seems like a simple task but I did what Greenleaf said and cut off the bracket and moved the intercooler tube and the throttle assembly bracket and then it wasn't too bad. I also changed the filter in the process and when I tried to start it, no go. I guess the fuel wasn't there yet and I panicked. Cranked a little with the throttle wide open and she went. Thanks everyone. How do you suppose they do it at the dealer shop? Must cost a fortune.

 

[Bob4x4]

Whew, what a job. Seems like a simple task but I did what Greenleaf said and cut off the bracket and moved the intercooler tube and the throttle assembly bracket and then it wasn't too bad. I also changed the filter in the process and when I tried to start it, no go. I guess the fuel wasn't there yet and I panicked. Cranked a little with the throttle wide open and she went. Thanks everyone. How do you suppose they do it at the dealer shop? Must cost a fortune.

See post #5



Bob

 

[JLEONARD]

Bob,

I reviewed that post and will put grinding the bracket on my todo list.

Thanks.

 

[dpuckett]

Ok, I have treid the 15/16 and 24mm wrenches. Rounded off the corners even more, so I ground it down to a tight 7/8. Rounded that off. Got a pair of 7" vice Grips (biggest I have- I cant find my 10" grips), and tightened them down so I had to use a set of Channel Locks to close them. Am in the process of rounding that off. I have already decided it is likely I will have to replace the solenoid, but I would like to just get the *$(%*$%@() thing off. Any other ideas? I'm stumped. I have PB'ed the snot out of it, too. Hit it with a hammer (vice Grips, not the solenoid itself), tried to turn it tighter to get it broke loose... ...



Daniel

 

[Don Tanklage]

i cant believe you havent resorted to GL's chisel n mer by now...



how long do these things usually last?

 

[TBurow]

i used a pair of knipex pliers, like channel locks with rounded jaws. fit right around it and made the job kinda easy.

 

[Don Tanklage]

did ya get it out?

 

[PToombs]

DP, not to be a wise a**, but did you have the vicegrips on the right way? They are directional. It shouldn't be in that tight!

How about small pipe wrench? That would bite good, then something on the handle for leverage? Good luck!

 

[dpuckett]

I didnt realize Vice Grips were directional, but it likely wouldnt matter with these.



I gripped the solenoid again with the Vice Grips, then got my pickle fork to use as a prybar on the Vice Grips, and against the p/s pump. Got it broke loose that way, with no damage to the p/s pump. Plunger had a big chunk out of it, and grinding it down to the metal took a lot of it out, but not all. I may get a new one anyway.



Now to find some hose fittings... ... Any ideas? See my other thread.



DP

 

[PToombs]

I'm going to pull mine again shortly. I ground it down so the rubber was gone. There is (was) a hole thru the middle, which I welded shut. Now it's too short, and sometimes stumbles along for a while, stopping if it feels like. I'm going to weld a nut on the end like Tommy on 1st gen. Hope it works!