Fuel Shutoff Solenoid Issues? | Here's THE FIX! | 1st Gen Cummins

[@johnfelton9021]

Extremely helpful! Same power loss occurred with me. Implemented your suggestions, one by one, starting with the fuel filter, then the updated lift pump and finally with the magic bullet (the last two from the Hungry Diesel). In my case, the o-ring had become enlarged on the FSS and so slipped down into the fuel passage where it blocked the fuel flow. FYI the Torx bit needed to move the plate is T30 and the Allen Head socket needed was a 5mm. I have an automatic transmission in my '93 and so I had to contend with an additional mounting bolt/location on the throttle assembly bracket. Not an issue. However, it did present a problem when trying to remove the top Torx headed bolt from the pump bracket. My solution was to use a Dremmel wheel to grind just a slight amount of relief from the bracket to allow just enough clearance to remove the bolt. An added step, but an easy solution if you are patient. Finally, when removing some of the bolts/hardware from the various brackets, be aware that some trucks may use SAE bolts and others may use Metric. Overall, your video was extremely helpful! Your channel is one of the best on KZbin for the DIY mechanic for these First Gen Dodge/Cummins trucks! Keep up the great work!

[@johnburns1453]

Mine has left me stranded three times over the years. Finally just gutted the solonoid and use a cable shut off,. But this sounds like a great fix and I'll likely order it !!

[@oby-1607]

My neighbor was telling me a story about when a wire fell off of this solenoid and she was going downhill with 4 horses in the trailer behind her. She was not impressed about the engine suddenly without warning shutting off in this situation.

[@johnburns1453]

She would have lost power brakes also with no engine vacuum !

[@kibbeekelley7195]

Thank you so much! these little tips saved me tons of time in broken bolts and bleeding knuckles. Much Appreciated.

[@scottbauer6232]

I did this upgrade yesterday on my 91.5 D250. Actually I did it 3 times. first time my truck would not shut down unless I cycled the key back on and then off again, then it shut down. So I took it back out and extended the spring length. Then it would try to turn the truck off but it still ran at a slower underpowered idle. So I took it back out and put the spring back to its original length and did some measuring and close observation of the old and new pin and discovered the new pin's brass end was a bit larger in diameter and the end of the pin was not countersank enough. So it chucked it up in my cordless drill and used sandpaper and then scotch brite to sand it down and polish it. I then used a countersink without a pilot to sink it deeper on the end. Now it works as the original one did. I only had to take the throttle linkage off and unplug the three wire connectors, they all had blade connectors and used a 15/16 crows, foot 6 inch extension and ratchet to remove and install mine.The trick is to install the crows foot first with the drive end facing the engine head then assemble the extension onto the crows foot between the pump and head. Stay Ultra Maga!

[@franklogan494]

Hi Tim, Thank you again for all the help!! For the last three day's my truck was belching black smoke and terrible idle at start up. Today after reconnecting the wires to the FSS, the truck started and ran like my truck again, it was as you said, the Magic Bullet.

[@decentgarage]

Sweet! Glad this was the fix!

[@OnefastAZfarmtruck]

I have the fuel cutoff hooked to a kill switch for a tractor in the cab. I like it because I can pull my keys out of the ignition and the motor still runs. Makes it easy to let it warm up in the morning with the doors locked or easy to take the keys out to get a gate and leave it running

[@decentgarage]

Yeah i ran the cable for a while but I'm liking being able to shut the truck off with the key now

[@itsaRiot]

Awesome video!! I have a 92 and a new fss. So when I jump the fss with a wire from the battery I hear the fss and something clicking in the driver fender...

[@decentgarage]

That would be your starter relay which is connected with your starter, your fss, and the ignition.

[@itsaRiot]

@decentgarage goddto know thank you! I was worried I had a major wiring issue. Love the builds keep em coming haha

[@tylerlockler6899]

I highly recommend The Hungry Diesel. Had my Ve pump rebuilt through them after it wouldn't start back up after getting the truck up to operating temperature unless I poured water on the injection pump. Stock rebuild but set at max fuel and it's got good power and idles waay smoother. Absolutely love that crew Cab. Great video, keep up the good work.

[@decentgarage]

Yeah, Eric does great work and is a stand up guy.

[@robroy5729]

what was the cost for the rebuild if you dont mind i ask?!

[@TheRoyalBavarian]

Thanks as always. I recently watched a video of someone else doing this and came away wondering , what ? Then I watched your instructional video and VOILA !!!!

[@decentgarage]

Excellent!

[@llamahunter3604]

Thank you so much for this! Worked perfectly! No more popping the hood and looking like an amateur 😊

[@josiahmalin8636]

I was going to just move that bracket but that one torx at the bottom stripped out. Now I have to cut that piece off. I was really hoping for this to be a smooth and not so complicated task

[@decentgarage]

Such is the life of owning a 1st gen. Sometimes easy projects have their hickups.

[@josiahmalin8636]

@@decentgarage that is no joke

[@rgdegregori8744]

I see you’ve had your fingers in there before. Those trucks came stock with a spade connector to the solenoid, you have a ring connector on a stud. I know because I had an intermittent loss of power issue. I called Jim Leonard a retired Cummins mechanic who I had met years before. He instantly knew the the problem immediately. I just crimped the connector with pliers an never had another issue. Some years later on a caravan camping trip to Baja my friend had his 92 shut down just above El Rosario. He started looking at fuel filters and fuses. I wiggled that wire and saw the connector was loose. There is so much vibration in the first generation all kinds of things work loose. After replacing front brake pads and putting new fluid in the system I checked the master cylinder over several days. Always had to add just a bit. I couldn’t see any issues with the calipers or wheel cylinders. Eventually I found it. The two lines coming out of the master cylinder have coils in them. They were close enough that when the engine was running the two pulsed together. It had worn a pin prick hole. One new line with better clearance solved that one. Keep up the great videos, thanks RD

[@decentgarage]

Yeah, i switched the ring connectors for this reason

[@johnburns1453]

I've had the same issue with the spade connectors .... When you say you crimp them with a set of pliers and your problem is fixed do you mean; A.) You crimp where the wire connects to the spade or B.) You squeeze the female end of the connector so that it connects tighter ? Thank you !

[@bbtoyshop]

Thank you so much for another very helpful and detailed video on possible issue with my truck I am going to see if this is the issue tommorrow my truck died on way to work I thought wire fell off the FSS like it has done before but wasn't the issue cranks over fine but won't start

[@decentgarage]

I bet this is your issue. You can pull the plunger and and run a pull cable in the meantime

[@bbtoyshop]

@@decentgarage I am hoping that is the issue it looks like it has fuel going to the pump so that sort of rules out the fuel filter and lift pump even though I have a THD pump I bought over a year ago when it went on sale for a price i couldn't pass up but still haven't put it on yet ..Thanks

[@decentgarage]

@@bbtoyshop I'll be making an install video for the hvlp lift pump next week.

[@bbtoyshop]

@@decentgarage Great I will be looking forward to it then I am subscribed to your channel Thanks

[@decentgarage]

@@bbtoyshop thanks man!

[@markroybal8958]

Once again man what an awesome video! I love that fact you take the time to show the step by step process keep them coming, I’ve got a whole video library full of them...oh btw I found a kick down cable 👍👍!

[@decentgarage]

Thanks Mark!

[@ebeegeebeefofeebee3181]

?

[@SkyR620]

Driving on Kansas roads. Truck suddenly acts like it ran out of fuel. Pull over. Sit. Start her up again. Drive another 25 miles. Repeat this 3x. Now in an RV park making repairs. With certainty it is the FSS . Filter is clean, pump is good and connections checked and rechecked. I will in the short term toss a kill switch/cable on it, but once back home I will replace the solenoid AND the pin. It looks as though you also good a new solenoid body that you put that magic bullet in. Is that the case or you just cleaned the old one up good? If a replacement, what did you use? Seeing all kinds of possibiliites with reviews all over the place. This is a solenoid that came with my new VE pump from Eric not quite 2 years ago. I would have expected the solenoid to last a bit longer than that but maybe they routinely fail? What say you? As always, THANK YOU for the vids. Saved me on that bracket info. Could not figure out how in the heck I was gonna get a wrench in there!!

[@decentgarage]

I did also order a new solenoid but that is not necessary. The hungry diesel carries them though. Glad this information was helpful in a pinch!

[@bobsethbroc]

Could you use a regular hex head bolts instead of the torq and Allen head bolts? Seems like a socket would be better

[@decentgarage]

You probably could but you will see when you pull them that they are all unique lengths. I am honestly not sure what their purpose is besides holding that bracket on.

[@Hardupgarage]

Awesome vid just bought my pin!! Keep being awesome

[@decentgarage]

Sweet! Let me know how it goes!

[@anthonyhill1303]

Mine had an issue where the solenoid would engage randomly while I was driving, killing the truck.. Must have been loose wiring now that I think about it, but I went to manual shutoff and solved the problem that way... Could have been my iffy wiring from fusible link delete..

[@decentgarage]

Did you follow my video for fusible link delete or did you use something else?

[@TheRoyalBavarian]

Tim do by chance remember what size that hex head is on the sliding plate ? Thanks.

[@decentgarage]

Shoot i don't... Sorry man!

[@faronf2006]

So glad you shared this video ...thank you !!

[@owenrigsby9764]

@decent garage I had electric issues and did a fuseable link delete and still have a crank but no start problem and I think it could have to do with the fss is there a fuse or something I can check

[@decentgarage]

There is no fuse to the FSS. If it is an FSS issues make sure the connectors are tight (I switched mine to ring connectors) and make sure the wires are solid.

[@jtuzil]

@@decentgarage could this be a relay issue? I just did the fusible link delete(windows and blower work now!) but it won't start. I played with the connections on the FSS but no luck.

[@wesleyd2511]

While you had the FSS gutted did you leave the wires all hooked up still? Thanks dude!

[@franklogan494]

Hi Tim Great Video!! What did you do about the KSB wiring once you disconnected the FSS, during cold starts you need this, as I found out after I deleted mine, as they are both connected through the same wiring. Thank you!!

[@decentgarage]

My FSS wiring and KSB wiring is still hooked up. The magic bullet still requires a functioning FSS. When i was running a pull cable shutoff i had my FSS installed with the wiring installed but i didn't have a plunger in it.

[@franklogan494]

@@decentgarage Thank you Tim!! Does that mean you can just join the two wires together or are there different voltage levels going to the FSS and the KSB through a relay?

[@decentgarage]

@@franklogan494 it should all be 12v 👍

[@franklogan494]

@@decentgarage Thank you!

[@clarin3318]

Saved me a bunch of trouble!!!

[@decentgarage]

Glad it was helpful

[@jond1536]

Great video, by the way have you figured out an easy way to turn off the Anti-Lock light issue (wiring from the anti-lock sensor on the third member) to the sensor box behind the glove box. My Pickup is a 91 (pre 91.5) non intercooled D 250 (2WD) ? besides just unplugging the box behind the glove box. The dodge fix is a real pain in the Gass to run another wire from the from the anti-lock solenoid mounted on the frame clear in the back all the way to the anti-lock control box behind the glove box. maybe you have done a video on this issue? just checkin

[@brianbuell8464]

Good stuff. Every time I see them workbenches I get ideas lol

[@decentgarage]

What ideas do you have for them? I have a love/hate relationship with them. I was just watching videos last night and getting some ideas for an overhaul of the Decent Garage.

[@samcssolutions]

Would this work on the White truck?

[@decentgarage]

Yes it would. I can help wyatt do it.

[@SterlingBall]

Just ordered one, put the fly wheel on today for a first start. After sitting awhile it stopped making any plunging noises while 12 v is applied 😅

[@SterlingBall]

I was thinking the ksb was it oops

[@SterlingBall]

Just changed wires and it fired up lol

[@TheRoyalBavarian]

Curious, is it possible to get a 15/16" socket on the solenoid ? Thanks Tim.

[@decentgarage]

I will of you get everything out of the way including the fuel lines for the injections pump. It's much easier with just an open ended wrench

[@unfknknown9678]

Would this blow a fuse if it failed causing the truck to not start?

[@billytraughber8427]

Could the fuel shut off ever be stuck in the off position causing the truck to not start?

[@lucascastillo2826]

Where to the wires from the fss go to?

[@decentgarage]

Through the fusible links

[@MrWoodnnails]

How did you get the pieces of the rubber plunger out of your fuel rails

[@decentgarage]

ehhhh.. Thats requires pulling the pump apart. Usually the pieces get stuck in the delivery valves which are easy to pull and check. So check there first. Or you can do like most people do and just run it. If it runs fine it probably won't be an issues. haha

[@redlined9192]

Im Looking for a kdp kit and cant find the oem seal one. Which kit do you reccomend?

[@decentgarage]

I don't buy a kit. I just make my own tab and buy a front main seal and a timing cover gasket from cummins.

[@jamesrichardson6725]

I have replaced fuel pump and filter and the truck after it gets down the road about 6 or 7 miles does not idle and shuts off and will not start till it cools off thought it might be this sensor

[@decentgarage]

I would be that it's your fuel shutoff solenoid 👍

[@fishiniseasy]

Have you ever dealt with the this issue? One day I was accelerating in my truck quickly and all of a sudden the truck cut off and white smoke started billowing out the tailpipe. I got all of my injectors tested and they checked out, and I replaced my fuel filter and lift pump. Now whenever I accelerate quickly the truck will blow white smoke and cut off. I’m hoping it’s not a cracked block or head gasket leak but I don’t know. Any insight you might know would help me

[@decentgarage]

Give me some more info. What turbo and injectors are you running? What kind of boost are you seeing. White smoke does usually mean burning coolant so you could have blown the head gasket.

[@fishiniseasy]

I have a Jm GSP turbo with “200HP” injectors. I’m not sure what boost I am getting because I do not have a gauge hooked up. I’ve just recently bought this truck and I do not know it’s history besides the description the seller gave me I’ve tried finding the exact turbo but without any luck, the injectors I have pulled to get tested and they were fine but they had no markings so I couldn’t get the exact details on those either.

[@dc_rubberduck6970]

My PCM is fried and idk where to source another do you have any ideas?

[@devinmanderson]

They are super hard to find. Cummins forum should be a good place to find help.

[@decentgarage]

They are hard to find. I see them come up used on facebook occasionally. There are a few companies that rebuild them but it is 300-500 bucks.

[@dc_rubberduck6970]

@@decentgarage what are some of the companies. I can’t find any. My truck has been down for about 2 weeks now.

[@decentgarage]

@@dc_rubberduck6970 i don't recall their names but one was out of texas and one was out of florida. If you go on the 1st gen cummins (89-93) facebook page and ask someone will know

[@georgeenriquez612]

Great video Tim!

[@decentgarage]

Thanks again George! 👍

[@DuddiesAdventure]

I've had the same problem except in the reverse. The Deathcharger wouldn't start. I gutted it and run a cable shut off. Since the Deathcharger isn't my daily I'm fine with it, but the ole COD may need it haha.

[@decentgarage]

Yeah, the cable wasn't terrible but it did get old. But for an offroad vehicle it would be fine.

[@gkolkman4]

Thank you from spruce grove Alberta

[@connorrobbins8862]

my truck is not starting was driving just fine then sputtered and died and will crank but not fire, its a 91 and I have gone through just about all i can think of but on my fss there is only one wire on it could this be the reason if so what wire is what

[@leonardomateos5572]

whhats the rubbere part on the right of the pump not connected to anything mine is leaking from there and cant find anything on it

[@armandomaldonado1559]

Where is this plunger at? Can you show it in your next video?

[@SuperAwesomestuff1]

My fuel gauge just sorta slides back and forth constantly. I also occasionally have issues with the other gauges in the cluster (speedometer just stops working sometimes) so I was thinking maybe it’s an electrical issue, but I’m not sure where to start looking for an issue. I’m not a mechanic and I’m learning as I go. Any advice would be appreciated. Thank you in advance!

[@decentgarage]

Great question. The fuel gauge in my prospector is doing the same thing so I'm going to have to look in to that and I'll do a video it. It's likely an issue with the fuel sending unit. The speedo issue is typically related to the vehicle speed sensor. If you do some googling about those things you should be busy for hours reading about diagnosing and fixing it.

[@SuperAwesomestuff1]

@@decentgarage thank you! I’ll look into it more this weekend

[@ronsre-creations5289]

Great Tip ! I will use that upgrade on mine. Thanks !

[@decentgarage]

Glad to help

[@austintipton3272]

Hey man I know it's off topic but would you be able to help me figure out some stuff on my truck. It's a 1993 dodge d-250 with a 12 valve automatic. I've never owned one before so I'm lost

[@bobpadilla4077]

does anybody know why the bracket is there and can it be just left off ? , thanks

[@PeachIsland418]

While my truck is a gasser, I have gas leaking into my oil. Could this be the cause?

[@zackebel2973]

No, you don't have this part on a gas vehicle. If you have a mechanical fuel pump though, that may be leaking in to your oil pan.

[@decentgarage]

^^^ What he said

[@levistory8575]

Can these solenoids fail shut? And cause the engine to not start?

[@decentgarage]

They are pretty basic solenoids. Key on power and they open, key off power and they close. I would suspect the wire connections being the issues before the actual solenoid failing

[@joshuafernau896]

I had the same question. My truck died a couple weeks ago it was 9 degs I wonder if the rubber tip broke off and is logged in the kill position? How can I recover it when I pull the old solenoid off? It just odd…

[@billbright1755]

I wonder if the solenoid can partially fail an allow engine to run above idle but stutter and shut off at idle. I think they should have used a much more robust and reliable system. Rubber chunks in the heart of the engine down stream of fuel filter,,, fail.

[@decentgarage]

Use promo code decen1stgen at wwwthehungrydiesel.com. Remember it's good for 10% off your entire order, not just the Magic Bullet!

[@dirtdiggler9293]

Fuse block is unavailable!! Do you have any suggestions because I blew my duck foot yesterday trying to fix my tail lights by “jimmy rigging”

[@shelby6722]

your promo code isn't working

[@decentgarage]

@@shelby6722 it might be because he has a 15% off sale going on right now for presidents day so they won't work together.

[@shelby6722]

@@decentgarage I'm not seeing that on the website and I don't see that it is giving me 15% off

[@decentgarage]

@@shelby6722 i believe for this sale all the prices are adjisted

[@sheldonernst3218]

Another Awesome vid! thank you

[@decentgarage]

Glad you enjoyed it!

[@wts860]

My o ring somehow lodged onto the tip

[@WIDEOPENPRODUCTIO100]

You can buy a brass tipped plunger for 30 bucks on eBay. It’s what I have and it works good

[@decentgarage]

Yeah I've seen those but I know the person who Eric sources these through and I 1) trust his work and 2) want to support his business.

[@mikestrucks]

Nice one 😉👍🏻

[@decentgarage]

Thanks 😁

[@devinmanderson]

Needing a cruise control unit and linkage for this set up anyone here can help.

[@trevorlee2484]

I may have something in the future

[@decentgarage]

I'll keep an eye out. I've never had working cruise in my truck haha.

[@devinmanderson]

@@trevorlee2484 kool beans man let me know

[@devinmanderson]

@@decentgarage thanks man ya its a pain not having one.

[@trevorlee2484]

@@devinmanderson Find me on the ol' FB

[@MegaRiffraff]

👍🏻

[@beretta989]

🇺🇸

[@decentgarage]

🤘

[@DASTrucks-q7p]

helpful and great! please remeber to take these adult diapers away from your camera

[@decentgarage]

I appreciate it!

[@promatskyline7608]

already use the cooper but still cant off my truck any solution sir?

[@decentgarage]

Stretch the spring out a little and make sure you don't have two orings down in there

[@MegaRiffraff]

👍🏻