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Battery Cables-Primary and Secondary, Diesel: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the battery cable harness from under the vehicle until the primary positive terminal and starter motor relay connections are positioned.
  2. Install the primary negative battery cable from the engine compartment until the terminal is positioned.
  3. Install the primary ground terminal and nut. Install the starter motor relay B+ and enable terminals and nuts.
    Fig 1: Installing Primary Ground Terminal And Nut
    G01440159Courtesy of FORD MOTOR CO.
  4. Install the primary ground wire and screw to the RH frame.
    Fig 2: Installing Primary Ground Wire And Screw To RH Frame
    G01440160Courtesy of FORD MOTOR CO.
  5. Install the primary battery ground wire and stud to the engine.
    Fig 3: Installing Primary Battery Ground Wire And Stud To Engine
    G01440161Courtesy of FORD MOTOR CO.
  6. Position the transmission cooler bracket on the stud.
  7. Install the battery cable harness through the engine crossmember, and position the battery cable harness bracket.
  8. Install the upper screw and lower nut to the front of the engine.
    Fig 4: Installing Upper Screw And Lower Nut To Front Of Engine
    G01440162Courtesy of FORD MOTOR CO.
  9. Connect the starter motor/solenoid ground, B+, and enable terminal wires and install the nuts.
    Fig 5: Connecting Starter Motor/Solenoid Ground, B+, And Enable Terminal Wires And Installing Nuts
    G01440163Courtesy of FORD MOTOR CO.
  10. Pull the battery cable harness through the body-to-frame ground strap.
  11. Install the three battery cable plastic locators in the RH frame.
  12. Install the three battery cable clip screws in the RH frame.
    Fig 6: Installing Three Battery Cable Clip Screws In RH Frame
    G01440164Courtesy of FORD MOTOR CO.
  13. Install the air cleaner assembly.
  14. Install the secondary battery cables and the secondary battery.
    Fig 7: Installing Secondary Battery Cables And Secondary Battery
    G01440165Courtesy of FORD MOTOR CO.
  15. Install the primary battery tray and bolts.
    Fig 8: Installing Primary Battery Tray And Bolts
    G01440166Courtesy of FORD MOTOR CO.
  16. Install the hold-down wedge and the primary battery.
    17. CAUTION: Failure to accurately follow the battery reconnect procedures outlined in this section will result in vehicle or component damage.
    NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM)  (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  17. Enable the vehicle electrical supply; refer to DUAL BATTERY DISCONNECT - DIESEL  in General Procedures.
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