Decided I'm going to replace the solenoid so the wife or anyone else can actually drive the truck if need be. I see some of you have mentioned having 2 wires on the top of the solenoid - I only have 1. Can someone enlighten me on what the other wire does. My truck seemed to work fine with only the 1 wire so should I worry about it?

Also, what size socket/wrench does the solenoid take?

 

the other wire would supply power to the ksb solenoid and temp sensor for it.

removing the solenoid is not easy. i successfully used a 15/16" crowfoot ground down on one side. others cut off the metal bracket.

-brian

 

My 91 had only one wire, my 93 has two....dont know why the diff....

 

The later style KSB draws power to the manifold switch via the shutdown solenoid. I remember reading about some trucks drawing the 12V from another source though, hence the single wire on the solenoid. Check to see that your KSB solenoid is getting 12V on a chilly morning. If it is, don't sweat it and just replace the shutdown solenoid with whatever you get. If the KSB is not getting voltage, you'll have to trace that wire back into the harness in order to find where things are going wrong.

 

Thanks guys. Another question - how does the plunger and spring stay in the solenoid while you are installing it? It just falls out once you turn it down.

 

You just drop it all in the hole at once. Keep your finger over the plunger until you have the solenoid almost in, the plunger will drop in where it belongs and the spring will stay on top of the plunger.

Hack the bracket, that extra piece coming up is just in the way.

 

Thanks Dave. It looks like the solenoid takes a 24mm wrench which I don't have so it will have to wait until tomorrow. I'm going to try a crowfoot wrench first and if that doesn't work I'll hack the bracket.

 

Do the threads need any sealant on them?

 

No there is/should be an o-ring on the solenoid.

Brian

 

The solenoid is actually a 24 mm part, but 15/16" is close enough especially considering you may have to grind away at the crow foot to get it to work correctly. Heck some mechanics at Cummins even use a hammer and chisel instead.

Brian

 

Hammer and chisel is what took mine out the second time when I gutted it. I just could not get it loose with the wrench. This last time I was careful and did not over torque it. The o ring does the sealing, not torque pressure.

 

Boatnik,

Hammers and chisels.... they're not just for fan clutches

Brian

 

the chisel attatchment on the air hammer works for me.