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

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 YouTube for the DIY mechanic for these First Gen Dodge/Cummins trucks! Keep up the great work!

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 !!

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

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

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.

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 👍👍!

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 !!!!

Awesome vid just bought my pin!! Keep being awesome

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.

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!

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

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

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

Great video Tim!

Thank you from spruce grove Alberta

Saved me a bunch of trouble!!!

Another Awesome vid! thank you

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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.

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