I have tracked my intermitant hard start to the fuel shutoff solenoid.The truck sometimes will not crank on the first try but will crank on second try and I have found that the solenoid is down on first try when not cranking.If I leave the key in the on position and hit it again it will fire right up when solenoid moves to up position. Is it possible that I may have a bad wire connection somewhere or is it probable that the solenoid is getting weak ? Where can I get the best deal on one ? Sure is tempting to just put a choke cable on it and never worry again.








95 2500 CC 4WD Auto 177K

 

It is impossible for the solenoid to get weak, either it works or it doesn't.
Your problem is not enough juice is getting though.
Relay contacts could be shot or the blue wire from the battery is corroded. The corrosion can be far down the wire under the insulation where you can't see it.

Also check that the solenoid boot is intact and that the solenoid isn't gunked or rusted up.

 

I just changed out the starter contacts with the big ones from Fosters. I was hoping this would cure it but it didn't. Where are the relays located and how can I check them ? I will also check the blue wire. Is it best to just replace the wire or should I check it with an ohm meter ?

 

Yours may look different, earlier models have another relay right next to the solenoid relay. The one you want is the bigger one. You can remove, take it apart and file the contacts but the results will be short lived, better to replace it.
The blue wire is actually called a fusible link, the wire is a fuse. Fusible links are available at any autoparts, the color indicates the amperage, buy a blue one.

 

thanks Infedel, I will order a new relay from Fosters, need a spare anyway. I checked the connections and everything seems to be fine, so I'm thinking relay may be on it's way out.