Building the perfect beast...some questions - Dodge Cummins Diesel Forum
94-98 Powertrain Discussion of components that are directly involved in the power production and all that is needed to get and keep the truck moving . Engine , Transmission Ect...NO ADVERTISING

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post #1 of 65 (permalink) Old 07-17-2018, 01:43 PM Thread Starter
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Building the perfect beast...some questions

I’m moving along as life permits with my ‘96 4x4 with a ‘00 quad cab project. My current question involves the shutdown solenoid.

When I got the truck, the HVAC fan, power windows etc. didn’t work. We traced that to a faulty ignition switch. The engine also would not shut down. I finally got around to troubleshooting and found the fuel stop lever wired open and the solenoid disconnected from it. I guess that was the previous owner’s solution to the switch issue!

Anyway, I tested the solenoid. It’s fine, but the boot is frazzled and it’s missing the little heim joint to connect to the pump lever. So here’s the question(s):

1) should I buy the whole shebang, or is it easy to find just the linkage and boot?
2) I see the solenoids from $22 to $300. What’s the middle ground? I never buy the cheapest parts, but dang! Is there a particular brand (besides Cummins) that’s good?


1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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post #2 of 65 (permalink) Old 07-17-2018, 01:51 PM Thread Starter
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And a clutch.

I’m considering the South Bend or Valair 13” single disc. Any recommendations for or against either, or another setup?

1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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post #3 of 65 (permalink) Old 07-17-2018, 05:25 PM
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Could you post a picture of what you have? I don't have a boot, but probably can resurrect the plunger. Genos sells the boot.

https://www.genosgarage.com/product/...lacement-parts

Both sell good clutches, both will recommend the right clutch for your application. I prefer SB.

97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #4 of 65 (permalink) Old 07-17-2018, 10:21 PM
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post #5 of 65 (permalink) Old 07-17-2018, 10:28 PM
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That's funny. I recently replaced my boot, purchased from Genos. It was a packaged Larry B boot and it cost less than what Larry B sells them for.

97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #6 of 65 (permalink) Old 07-18-2018, 01:41 AM
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Larry B sells all the little parts for the solenoid, as well as many other quality parts for our trucks, at a good price. Always who I go to for that stuff.

As for a clutch I will always buy south bend. I have never had a problem and everyone else I know runs them with great results. I have heard of horror stories with valair....but every time I bring it up others defend them almost militantly

1996 2500 ECLB, NV4500, 4X4
Engine: 24 Valve P-Pump Swapped,
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post #7 of 65 (permalink) Old 07-18-2018, 10:37 AM
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Quote:
Originally Posted by colin91 View Post
Larry B sells all the little parts for the solenoid, as well as many other quality parts for our trucks, at a good price.
I agree. I remember when he was a basement enterprise and only sold the over sized contacts. Now Denso has incorporated them into their new starters, but only on ONE side. I also remember when he charged $30 for the boot.

I asked for a picture of what the OP has because I have some piece parts to a FSS and if I have what he needs I'll give them to him.

97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #8 of 65 (permalink) Old 07-18-2018, 01:49 PM Thread Starter
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Thanks for the help, and I’ll try to post a pic when I get home. Basically I just have the plunger with a threaded hole in the end of it. Just missing the eye that connects to the lever on the pump.

I’ve been thinking about putting a shutdown cable on it just for laughs. I remember back when I started as a diesel mechanic in 1995, most of the trucks in the fleet had cables. In fact, the first shutdown solenoid I remember seeing was on a 8.3 B-series. Those were the days! Now I can’t fix sh!t without a laptop and an internet connection..,

1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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post #9 of 65 (permalink) Old 07-18-2018, 02:04 PM Thread Starter
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I’ve also been drooling over CAD deletes and locking hub conversions. A man could drop a ton of loot in a hurry!

I had saved up 15k while I shoppped for the truck, seemed like that’s about what nice ones were going for. My requirements were ‘96-98, 2500 extended cab 4x4 manual trans longbed

Since I paid $5800 for the truck, I’m prepared to spend some to make it the way I want it. That includes replacing every belt/hose/bushing/ball joint. I’m a maintenance nut and I hate breaking down over dumb stuff. The rest of the list includes:
KDP tab
PowerDriven fueling kit with AFC Live
Retorque head
Gauges
Clutch
5th gear nut
Fresh brakes as needed
Fuel gauge sender
Brake controller
Wheels and tires
Remove sillyass leveling kit,
Good shocks

1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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post #10 of 65 (permalink) Old 07-18-2018, 02:30 PM
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I think they got rid of the heim joint sometime mid 95.

I'm way to lazy to change my fuel senders I have new ones for both trucks.

I can get 600 miles to a tank and not have starvation issues easy.

Daily driver/ workhorse: 1994 2500SLT 4x4 Auto. Hewitt EGT, Boost, Trans gauges, Under hood Mech FP gauge, Trident fuel lines, Tork Tek OFV, Mag-Hytec DD Transmission Pan, Ford manual hub conversion, Diamond eye 4" turbo back, 37337 Upgrade. 260K

98 2500slt 4x4 ECLB moldy G56, south bend clutch 3rd gen trac bar , boxed control arms, billet tappet cover w/ dual breathers trident fuel lines, Tork Tek OFV, 4' stainless side dump with muffler 240k
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post #11 of 65 (permalink) Old 07-18-2018, 02:55 PM Thread Starter
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Yes, I see that the eye is a square end on LarryB’s. Looks like I can get the boot and the link for <$20&#x1f603;

1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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post #12 of 65 (permalink) Old 07-18-2018, 03:04 PM Thread Starter
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Quote:
Originally Posted by alanack6795 View Post
I think they got rid of the heim joint sometime mid 95.
In m
I'm way to lazy to change my fuel senders I have new ones for both trucks.

I can get 600 miles to a tank and not have starvation issues easy.
That’s how I roll in my other truck. Start looking for fuel around 500 miles. On this build, though, we’re removing the bed for awhile so I can leave it at my friend’s body shop. I’ll put it on sawhorses in the corner and he can work on it as time (and actual paying customers) permit.

1996 2wd 5speed, AFC Live and boost elbow ,otherwise stock.

1996 2500 4x4 5 speed. Bone stock
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