started having problems with my fso solenoid a while back and have been having to lift it up manually to start the truck, but once it has been running and warmed up and then shut down, i can start it again without having to push it up by hand. does this rule out the relay and mean that it is the solenoid itself that is hanging up?

 

What kind of voltage if any, are you getting at the solenoid when you first crank it?

 

Could still be the relay. The relay with care can be taken apart and contacts cleaned. See pics in my photo gallery.

Otherwise, the solenoid could be hanging up on the dust cover, but does not sound like it (if it was dust cover it seems like it would be more random).

If the cover did fail, dirt and junk could be causing the problem. Personally I would take both relay and solenoid apart, clean em up and reassemble. Your only out some time.

I used fine wet dry paper on the relay contacts, and contact cleaner. For solenoid, contact cleaner and a light spray lube, but my solenoid was not dirty inside. Also make sure blue wire on battery is making good contact, it is a known failure point. KD

 

Also clean the battery terminals really good. The high current lead to the cutoff solenoid comes off the + terminal on the driver's side battery. If that area gest corroded it can cause the solenoid to sometimes not engage.

 

I had to turn my key on and manually puch the plunger up too untill i just rana wire from the solinoid to a switch and then to the relay...its always the relay thats bad(most of the time) theres a wire that when u turn your key on gives it high current to suck the plunger up and then theres low current that keeps it up untill u shut your egnition down...u just need to jump the high current wire. i can get the wire colours if your interested in jumping it...its also werkd as a good theft detourant to....no one u dont want will be starting ur truck if they dont know bout that lil button u install