Have had this 96 for about a year and 1/2 and it's my first diesel. A few weeks back I was having startup problems, which after much research and investigation, led me to almost understanding the the fuel shutoff system. After first replacing the shutoff solenoid(wasn't that) then the shutoff relay(wasn't that), I started checking all wiring related to the system. Got a lot of great information on this site and was able to troubleshoot and eliminate most possibilities, but the brown wire that runs from the starter solenoid to the shutoff relay that activates the pull coil in the shutoff solenoid may be my problem, but I cant seem to find much info on that. Where the brown wire is connected to a small lug on the starter solenoid, the lug was loose from the solenoid housing. After snugging up the lug I was able to start up with no problem, but I don't feel like this is a permanent fix. Any info about the brown wire or the lug or what it's connected to in the starter solenoid would be greatly appreciated.

 

the solenoid pulls up only when you turn the key to start, it only gets power on that wire while the key is in the start postion then the constant 12v keeps the electromagnet working after its pulled up until the key is turned off. the small post on the starter is what i call the trigger wire or the one that gets power from the ign when you turn the key to start so they are just jumping up to the solenoid from there since it also needs power at key start postion

your problem should be fixed for good

 

Thanks for the reply Dustin. The small post on my starter was detached from where it was mounted on the starter solenoid, and seemed like it was just hanging from a wire from inside the solenoid. The post did not thread into the fitting but more or less plugged back in. It didn't seem super secure, which is why i felt like it wasn't a permanent fix. I reckon I'll just wait and see what happens now unless you or someone else has some other ideas. I'm trying to avoid pulling the starter if I can, but that might be the next step. Thanks again for the input.

 

If it happens again you will have to replace the starter to keep it from doing it again

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