Went to start my '91 GV Saturday and none of the gauges came on except for the air pressure but the engine started. Did not have a meter with me so I went back today with tools to see what was wrong. Gauges came right up the first time. After getting pressure up I shut it down and then turned the ignition back on and this time the gauges did not come up. The next time the gauges came up but after a delay. After switching it off and on a number of times the problem seems to be solved. It appears that the Ford starter relay in the dash was sticking from disuse. I want to get a spare relay just in case it decides to stick again. What do I need?
John,
If you are talking about the IGNITION SOLENOID, is may look like a Ford starter solenoid, but is A CONSTANT/CONTINUOUS DUTY SOLENOID.
Many have upgraded to a Bluesea electronic switch. Have never heard of a failure: L Solenoid - 12/24V DC 250A - Blue Sea Systems (http://www.bluesea.com/products/9012/L_Solenoid_-_12_24V_DC_250A)
But, I would start by verifying that you are getting the 12 VDC positive signal from ignition switch to the solenoid. Said another way, it is difficult to determine whether this is an ignition switch issue or solenoid issue without troubleshooting.
You can also jump from the "battery side" lug of the solenoid to the 12 VDC positive signal terminal with a small wire. That should make the solenoid close/provide power. That wire does not need to be large gauge, since is is only drawing current to close the relay, but be careful not to touch any metal/ground with it!
Having been a VW mechanic in the early '60's I am VERY familiar with starter solenoid issues. We would install a real Ford 6V relay to provide power to the starter solenoid because the current from the ignition switch would not be enough to cause it to engage the starter gear. See my new post about current needs.