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Battery Cables - 6.0L Diesel: 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.
NOTE: This procedure covers the removal of the battery cables and the batteries. Perform only the steps necessary to remove the appropriate part(s).
  1. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
    2. CAUTION: Failure to accurately follow the battery disconnect procedures outlined will result in vehicle or component damage.
  2. Disconnect the jump-start connection by removing the 2 jump-start connection bracket bolts.
  3. Open the battery cable wire retainer between the secondary and primary batteries to remove the battery cables.
    Fig 1: Identifying Battery Cable Wire Retainer
    G02766702Courtesy of FORD MOTOR CO.
    4. CAUTION: To prevent possible damage to the 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 Secondary Battery Case From Frame
    G02766703Courtesy of FORD MOTOR CO.
  4. Remove the secondary battery case from the frame.
    1. Remove the RH secondary case-to-frame bolt.
    2. Loosen, but do 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 battery case until it rests on the safety straps.
  5. Open the battery cable wire retainer located in the front of the primary battery and remove the battery cable.
    Fig 3: Identifying Battery Cable Wire Retainer
    G02766704Courtesy of FORD MOTOR CO.
  6. Remove the body-to-frame ground bolt.
    Fig 4: Removing Body-To-Frame Ground Bolt
    G02766705Courtesy of FORD MOTOR CO.
    7. CAUTION: To prevent possible damage to the 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 5: Removing Primary Battery Case From Frame
    G02766706Courtesy of FORD MOTOR CO.
  7. Remove the primary battery case from the frame.
    1. Remove the RH primary case-to-frame bolt.
    2. Loosen, but do remove, the 3 remaining battery case-to-frame bolts.
    3. Raise the battery case up and to the right to dislodge the battery case from the 3 remaining bolts.
  8. Remove the primary battery case cover.
    • Remove the 2 attaching bolts.
    Fig 6: Removing Primary Battery Case Cover
    G02766707Courtesy of FORD MOTOR CO.
  9. Remove the secondary battery case cover.
    • Remove the 2 attaching bolts.
    Fig 7: Removing Secondary Battery Case Cover
    G02766708Courtesy of FORD MOTOR CO.
  10. Disconnect the battery cables from the primary and secondary batteries.
  11. Remove the 3 harness locators, along the RH frame rail, and pull the harness through the front body mounting point.
    Fig 8: Identifying Harness Locators
    G02766709Courtesy of FORD MOTOR CO.
  12. Remove the 2 harness locators in front of the front body mounting point.
    Fig 9: Removing Harness Locators In Front Of Front Body Mounting Point
    G02766710Courtesy of FORD MOTOR CO.
  13. Remove the starter solenoid wiring.
    1. Remove the protective cap.
    2. Remove the solenoid enable terminal nut.
    3. Remove the solenoid enable cable end.
    4. Remove the solenoid B+ terminal nut.
    5. Remove the solenoid B+ cable end.
    6. Remove the starter cable hanger stud nut.
    7. Remove the starter cable hanger.
    Fig 10: Removing Starter Solenoid Wiring
    G02766711Courtesy of FORD MOTOR CO.
  14. Lower the vehicle. For additional information, refer to JACKING & LIFTING .
    15. NOTE: Battery junction box (BJB) cover removed for illustrative purposes.
    Fig 11: Removing BJB Battery Cable Nut And Cable End
    G02766712Courtesy of FORD MOTOR CO.
  15. Remove the BJB battery cable nut and cable end.
  16. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  17. Remove the battery cable harness from the wheelwell area.
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