Common problems and there fixes
Problems that will cause "No start":
The blue fusible link
is a common problem (Diagram HERE
), it fuses the "Pull" wire going to the FSS. On the 94-97 it is located on the drivers side positive battery terminal. it often gets corroded at the connector or inside the insulation, go to your auto parts store and ask for a "14 ga fusible link" (it might not be blue but that does not matter there both the same) then cut the old one off and use a crimp connector to install the new one.
(not sure about 98, if you have info please PM me, I will try to get the info ASAP)
is located on the fire wall in picture below (it's the bigger one), Part# SS70A, this relay is what gives power to the "Pull" wire to lift the lever when the starter is engaged. Here's a good place to get the Relay LarryBs.com Dodge
the Boot will often rot off and let dirt on the shaft which will cause it to get stuck, To clean it and replace the boot, simple remove it from the truck. Cut any zip ties off that may be holding the old boot on. Use a rag and clean off the plunger and the bore. When reinstalling, I used a little grease, just make sure not to use to much as it might make an air tight seal and not let the plunger lock up, causing the truck to shut off once you let off the starter. If your boot is rotted then it would be best to replace it, Here's a good place to get a new boot LarryBs.com Dodge
A how-to video >
Truck Starts and shuts off
Check the FSS connection and make sure it's not corroded. and check to see what all things you loose when the truck shuts off, gages/lights/radio/etc. The hold wire is fed by the 'green w/black stripe' wire. that's the same wire that powers a bunch of other things. so that's probably your problem if you loose gauges, radio, ect. Refer to the wiring diagram
FSS Out of adjustment
. This isn't very likely unless you just replaced or monkeyed with the FSS. In which case adjust it as needed Fuel Shut off Solenoid (FSS)
. Just like with the rotted boot, if the plunger can't go up all the way because the rod connected to the lever on the Injection pump is adjusted to short, the hold coil will not be able to keep the plunger up, and the truck will shut off once you let off the starter.
Low power/will not rev as high
Fuel shut off lever not coming up all the way
There's two things that can happen, A) the FSS can get dirty so the shaft doesn't come up all the way (refer to "rotted boot" just a little ways up). B) The FSS is not adjusted correctly, Go HERE
to see how to adjust it, if it's not adjusted correctly, adjust the FSS shaft as necessary
Won't Shut-Off, or Shut-Off is delayed.
Check 'Rotted Boot' above
Missing Woodruff Key on FSS Shaft
If the key is missing, the lever will just spin on the shaft and may not allow the engine to shutdown, or just delay shutdown. Once started, the engine may act normal, or be low on power. After uninstalling the FSS, You can loosen bolt 'C' in THIS picture
to slide the lever off the shaft and insure the keyway is installed as it should be.
a picture of where the key should be.
The Woodruff key part number is Cummins 3920924 or Mopar 04761316. CumminsForum member thecheese429 reported that a 2mm X 3.7mm woodruff key he found at ACE hardware was also the correct size, and could be had for a couple bucks.
Notice I didn't say anything about replacing the FSS its self, there's a reason for that. it almost never fails and if it does you can normally tell by looking at it that it is burnt. in which case you can get one from here LarryBs.com Dodge