Posted by Fritz Maurer on November 10, 2012 at 17:56:22 from (216.137.138.146):
In Reply to: Ford 7.3 diesel posted by Mark-Ia on November 10, 2012 at 14:50:29:
Ford Diesels through the years all had the same problem with the solenoids... dirty connections lead to high heat ending with crumbling solenoids. Although my 7.3 knowledge ends at 1997, the fix is the same. MAINTENANCE!! You must inspect these connections regularly to avoid the problem you face. Diesels have a sharp, fine vibration that loosens things. Add to that vibration a heavy, stiff electrical cable and you will eventually have trouble. I had a '95 that would wolf a 80.00 glow plug solenoid yearly. In that particular case I mounted the solenoid on a piece of tire so the solenoid could flex with the wires instead of working against them. Also beneficial is Never-Seez on the terminals. The reason the solenoid nuts are rusty is they were overheating, mostly due to a loose connection. Then the rust adds resistance, and more heat. The Never-Seez melts slightly under normal operating temperature, and forms a protective coating on the connection, so if it loosens up,it won't rust right away. Sometimes the solenoid must be removed to service the engine, and Never-Seez saves damage to the solenoid if the nuts get rusty. Regarding the solenoids themselves, I would buy them from Ford. This is not an expensive option when they're properly cared for. If you get them from the auto parts store, they may look the same externally, but they could be circuited differently internally. The wrong wire grounded in an unfused circuit from the powertrain control module will result in way more expense than the cost of an OEM part.
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