This fall my fuel shut off solenoid crapped out. This happened after a pump adjustment. I was driving to a local truck pull. When I got there the truck wouldn't shut off. Since then I've been using a manual shut off cable.
Today i pulled out the shut off solenoid. There was no rubber left on the plunger. But the worst is it looks like a piece of the plunger is broken off. And It was not found.

 

Join the club. If it didn't fubar the pump right when it happened, I hear it just ends up going through the injectors. Worst case is pulling the Delivery valves cleaning them and cleaning the injectors. But if it's running good then I wouldn't worry to much about it.

 

If you look at the pin it looks chiped. I don't want that piece floating around.

 

I found mine in the delivery valves

 

Big job taking them off. Did you pull pump off engine to get them off?

 

The injector feed-lines connect to them at the back of the injection-pump . . . .

 

I will be swapping injectors this winter so the lines will off. Does anything else fall out when they are removed?

 

Yes there is a spring and one or two other little pieces. I had the same issue with the fss and I found the pieces in the delivery valves. If you replace the fss make sure you look in the sticky about the cheap vw replacement part and how to modify it to make it last longer.

 

My FSS looked about the same as yours, it had a big chunk off one side past the metal part in the middle. I took it to a bench grinder and ground the rubber off down to the metal even though it had a little chunk missing below the metal, I just buffed the edges with a little emery cloth and put it in and it works. Which is nice cuz now I can use my cooldown timer. So I'd say try grindin it down and put it and try it, its already somewhat ruined so you can't hurt it anymore. I did this a few months ago and its been shutting it down fine ever since. As far as where the rubber went, I'm not sure. The truck ran fine ever since it blew about two years ago, so i figured to leave it, You'd think that the high pressures would break the rubber down after a while and just send them through. I did get new injectors since then but never checked my DVs, but its ran fine.

 

Fix your shut-off solenoid ~ https://www.dieseltruckresource.com/...d.php?t=117593

 

I would pull the pump so it can be vertical and less chance of loosing parts. I would also wait til you had planes on doing the objectors so it all gets done at once.

 

Can I leave the plunger and spring out and just put the soleniod back in as a plug. I would continue to use a manual shut cable. Injectors are part of the winter plans.

 

Yes, put the oring back on. Thats how mine is done and it's an anti theft device also you can leave it in the "off" position and no one could start your truck, unless they knew to push the cable back in.

 

Is there a reason for the bracket on the back of pump

 

Um hold up the back of the pump? I know where you're going with this....I think? I cut the top part off that is just hanging up there and getting in the way to get the fss out/in. After 50k it's still just fine. But the rest of the bracket that is holding the pump up is still there, I just cut it flush with the top of the pump.