Engine/Transmission (1994 - 1998) Run on problem and no power

[foxt]

I have a '95 2500 with 160,000 miles. For the last few months, I have had to manually push up the fuel cutoff solenoid with the ignition on to start the truck. I did swap the relay, but it still needs to be manually actuated. The boot seems long gone, so I assume I need to take it apart, clean and lube it, and replace the boot.



Today, the truck would not shut down after I turned off the ignition. From other posts, it looks like this could be related to a sticky shutoff solenoid. I can get the truck to stall by turning off the ignition (the truck still runs at this point) and then putting it in gear - it will stall. However, if I start it back up and then attempt to drive (with the ignition on), I have no power - I can get up to 40 - 50 mph on a flat road, but more like 10-15 mph on a hill. This just started happening with the won't-shut-off problem.



Are those related? I don't rely on the truck for transport, it's more of a special purpose thing for me, so it also sits idle for a long time. My brother recently added some home brew diesel (tank probably has a 50/50 mix) and I've heard that might act like a solvent and clog my filter - I am wondering if that could be related to this? Or do I need to just tackle these one at a time - fix the sticking fuel shutoff solenoid first and then see what happens?



Tom

 

[GAmes]

One thing at a time. First, pull the solenoid off and clean the bore and plunger. The most difficult part is removing the hairpin that holds the rod to the lever without dropping/losing it. I use a shotgun brush for the inside of the bore. Put a little dry lube on the plunger and reassemble. You do not need a boot, I haven't had one installed for years. Your partial power problem could very well be the solenoid plunger is not fully up which in turns fails to fully pull up the lever it is attached to, but could also be the home brew. Fix the solenoid first.

 

[hsmith]

I agree with Gary. You probably have more than one problem here. Do the solenoid cleaning, replace the fuel filter, and clean the prefilter screen.

 

[foxt]

Ok guys, thanks. I'll tackle the fuel shutoff tomorrow and report back.



Tom

 

[foxt]

I took the solenoid off, and discovered that the old boot had disintegrated in such a way so as to get caught up in the spring, which was probably preventing the piston to be forced all the way back out.



Cleaned everything up and reinstalled (without a boot). I still need to manually lift the piston, so I need to chase that. However, truck shuts down now after I turn the ignition off, and seems to have normal power after a short test drive, so I'm figuring that my issues with shut down and lack of power are resolved.



About that boot - I've seen a few posts from folks who say that they haven't replace theirs, and they haven't had any issues. What do you guys think?



Tom

 

[RIT]

I removed the boot off of my solenoid about a year ago and have not had any problems with the functionality of the unit. I am sure it will cause problems if your truck goes off-road frequently. The boot is there to keep dirt from getting on the piston and limiting travel. Its kinda funny that the boot will eventually break apart and cause the problem that it was put there to prevent.

 

[Missouri Mule]

My boot fell off several years ago. No problems as of yet.

Check blue wire at battery it connects to a fusible link that goes to the fuel shut off solenoid relay.

Make sure the relay is working.

Check for broken wires going to solenoid/relay.

 

[KB0OU]

I put a cable on mine, no more selinoid.

Simple and it always works.

 

[WilsonF]

If you want to replace the boot you can get them through Geno's or Ebay. Some just cut a bicycle intertube and put it on.

Floyd

 

[foxt]

Thanks to all for the help. Looks like my blue wire is damaged a bit at the connector on the battery. Glad I checked that before picking up a relay. I like the idea of replacing the whole setup with a simple cable, might just have to take a crack at that.



Tom