My truck wouldn’t start yesterday So I started troubleshooting the fuel system. I determined that the solenoid wasn't pulling on start but would stay up if I pulled it manually. I found that the relay contacts were burned and after filing them the truck starts fine.

I removed the solenoid to check it over and see that the rubber boot is completely dry rotted. Anyone know a source for a replacement boot?

Bob

 

www.fostertruck.com for the boot and for starter contacts

 

If you have some old mountain bike tubes lying around, you can make one pretty easy with that and 2 zip ties. Otherwise fostertruck is the place to get stuff like that.

 

You mentioned the relay contacts were burned. Are you referring to the fuel solenoid relay mounted on the engine cowl or the starter contacts? If the relay, I guess you pulled it apart to fix it. The foster truck website also has the relay but it can be found cheaper too? I'd replace the relay and keep the old as spare but to each his own.

 

use a rubber (jimmy hat) and 2 zip ties. the mountain bike tubes are a little on the rigid side.

 

Just had that lying around did ya?...

 

A short length of bicycle tube zip tied on each end works great. I did mine a few months ago and all is well. I think if you buy one, it will run over $20.

Good luck.

 

I used a piece of bicycle inner tube on a tractor solenoid that has an identical boot. So far, it has worked fine.

 

I was thinking about a bicycle tube last night. It would be about 1/10 the price of a new boot.

The relay was burned. I am talking about the relay on the cowl. I used three screwdrivers to pop it apart and I removed the contacts and filed them. I am ordering a new one from Rock Auto and keeping this one for a spare. I know it will fail again someday.

 

The boot does more than just provide protection. At least it did on the one I made from an inner tube. The boot also locates the solenoid plunger in the off position. If the boot is too long, the solenoid may not pull in far enough for the holding coil to grab it. If you make one, and all the solenoid does is click, shorten the boot a bit.

 

Or go with no boot. I haven't had one for over 300k miles. I do pull it apart about once a year for cleaning and some dry lube..