Component identification and troubleshooting advice

[Jameson]

Good morning all. Working through a mechanical problem somebody on here may be able to assist with.

I have a mechanical 8.3 in a 94 Bluebird AA. Lost power yesterday and have a no start condition this morning with plenty of engine rotation.

I have little trouble shooting experience on diesels, but visually I believe I have it located to the component pictured. The male rod continues to fall out of its mating surface which is hidden under the rubber.

If I hold in place, she starts and idles, but falls out quickly with a touch of the throttle.

Could something else be causing or is the fix as easy as a component replacement?

Thanks in advance if anyone can assist.

[TJones]

Looks like a fuel shut off solenoid. Does it have wires or an air line running to it?

Ted

[Jameson]

Originally Posted by TJones

Looks like a fuel shut off solenoid. Does it have wires or an air line running to it?

Ted

It is electrically actuated, and operates when ignition is on pulling what feels like a spring up which the male rod on the bottom falls out of. Its labeled with "synchro start".

Thanks for the quick reply.

[magnakansas]

I wish we had a picture a little further away, we could then see the context of the part you have pictured.

A band aid for this is a wire tie, wire, shoe string, something to hold it in the up position.

This part is a common failure on dodge pickups. So common, that this part is in a box I carry on the bus for roadside repairs. I think the 8.3 pump is the same as on a 1995 dodge 3500 with a cummins 5.9 - called "fuel shut off solenoid"

do you have a test light? or a multi meter? or even a piece of wire? should test if the unit faulty or the unit is not getting power. First.

william

[magnakansas]

so it works, we need a better picture of the where that rod is falling out. possible you have all you need to put back together but also possible you are missing a bit or two.

william

[Jameson]

Originally Posted by magnakansas

I wish we had a picture a little further away, we could then see the context of the part you have pictured.

A band aid for this is a wire tie, wire, shoe string, something to hold it in the up position.

This part is a common failure on dodge pickups. So common, that this part is in a box I carry on the bus for roadside repairs. I think the 8.3 pump is the same as on a 1995 dodge 3500 with a cummins 5.9 - called "fuel shut off solenoid"

do you have a test light? or a multi meter? or even a piece of wire? should test if the unit faulty or the unit is not getting power. First.

william

Thanks! I'm in friendly territory so going to go for a permanent fix. Heading to Napa now and going to disassemble this afternoon. Will let you know, good tip to carry a spare!

[TJones]

If the rod is coming all the way out ofthe housing it is broken. If it failing to pull in when the ignition is on it could be bad or just not getting power. It does look like it is farther outh than it should be.

Ted

[Jameson]

Thanks gentlemen once again. Looks like there is a worn out expanding snap ring that is allowing the male end to fall out. Electrical portion functions.

Despite my desire to avoid an expedient repair, parts are not available in Alamogordo NM like I got used to in Albuquerque. This is the ugly but functioning solution.

My understanding is that this is a simple on or off solenoid, no metering of fuel, so I can clamp open if my mess fails on the road.

Southeast bound!

[Jameson]

Wrote to soon. Waited for daughter to wake from nap to function test. She cranked, started, and immediately died three times and now I have zero cranking...

Good times.

Hoping that my repair damaged the electrical connection in the solenoid and that is preventing current from getting somewhere the starting system needs it.

[Omingnome]

I had issues with me fuel shut off solenoid on the 5.9 (looks identical to yours)

Add a mechanical push / pull cable and bypass the electronic solenoid completely - some cummins folks say they fail repeatedly - mine smoked really bad and gave us quite a scare, so I got rid of it - plus it turns it into a $25 fix instead of $150 or so to replace it.

I mounted mine next to my e brake push / pull - plus it makes for a hell of a security device - few people would think to pull a cable prior to turning the ignition

[Tango]

What he said. Dump the problematic solenoid. A simple cable (or in my case, push/pull rod) will make life SO much simpler. The solenoid is one of the Cummins few real weak spots but is easily overcome.

[Jameson]

Thanks again gents. I like the idea of theft prevention and simplicity! I had not considered running a cable yet.
I went with a new solenoid to get the family back on the road, getting to cold here with no ceiling insulation!

[Elliot Naess]

What they said. Toss the solenoid. And then you might as well also toss the electronic timer that manages the voltage to it -- less Useless Stuff hanging on the engine. Then connect an old-fashioned manual choke cable or similar. Amazingly, auto parts stores still carry them.

[Tango]

Here is my solution to the whole, expensive, troublesome solenoid issue...



Quarter inch rod and a Heim joint. I don't even trust that fancy cable stuff!
Plus...you get to add a really sweet cherry red knobby thing on the dash!

[Elliot Naess]

The cherry red paint wouldn't stick to the knob I made.

[Tango]

Sweet! Do what works!