Battery - Auxiliary: Removal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.

WARNING: Keep body from under the auxiliary or secondary battery when disconnecting or reconnecting the auxiliary battery safety straps since the battery weighs 50 pounds and bodily injury can result. Failure to follow these instructions may result in personal injury.

CAUTION: Failure to accurately follow the battery disconnect procedures described in this section may result in vehicle or component damage.

NOTE: The preferred method of service requires the use of a floor hoist to lift the vehicle overhead, and a transmission jack to support and lower the auxiliary battery case.

NOTE: The auxiliary battery can be charged while the auxiliary battery safety straps are connected to the vehicle. Follow the procedures up to and including disconnection of the auxiliary battery cables.

Disable the vehicle electrical supply. For additional information, refer to DUAL BATTERY DISCONNECT .
Remove the two auxiliary battery cable harness screws retaining the harness to the frame.

Fig 1: Removing Two Auxiliary Battery Cable Harness Screws
Courtesy of FORD MOTOR CO.
Support the bottom of the auxiliary battery and case with a transmission jack.

CAUTION: To prevent possible damage to the auxiliary battery case, cover the battery cables during the lowering process. It is recommended to loosen the auxiliary battery case cover bolts before lowering the battery box.

Fig 2: Removing Remaining Battery Case-To-Frame Bolts

Courtesy of FORD MOTOR CO.

Remove the auxiliary battery case from the frame.
1. Remove the upper RH auxiliary case-to-frame bolt.
2. Loosen, but do not remove, the three remaining battery case-to-frame bolts.
3. Raise the battery case up and to the right to dislodge the battery case from the three remaining bolts.
Lower the auxiliary battery and case until tension is present on the safety straps.

Fig 3: Identifying Safety Straps (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 4: Identifying Safety Straps (2 Of 2)
Courtesy of FORD MOTOR CO.
Remove the two bolts and disengage the battery case cover.

Fig 5: Disengaging Battery Case Cover
Courtesy of FORD MOTOR CO.

Fig 6: Removing Two Bolts
Courtesy of FORD MOTOR CO.
Remove the auxiliary battery cables.
Remove the two auxiliary battery case safety strap to frame bolts.

Fig 7: Removing Auxiliary Battery Case Safety Strap-To-Frame Bolts
Courtesy of FORD MOTOR CO.
Remove the hold-down wedge.

WARNING: When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.

Support the battery and case with a transmission jack. Disengage the safety straps and roll the auxiliary battery and case on the transmission jack away from the vehicle.