Battery Cables - Auxiliary, Diesel: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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).

Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .

CAUTION: Failure to accurately follow the battery disconnect procedures outlined in this article will result in vehicle or component damage.

Disconnect the jump-start connection by removing the 2 jump-start connection bracket bolts.
Open the battery cable wire retainer between the secondary and primary batteries to remove the battery cables.

Fig 1: Removing Battery Cables
Courtesy of FORD MOTOR CO.

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.

Remove the secondary battery case from the frame.
1. Remove the RH secondary 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.
  - Lower the battery case until it rests on the safety straps.
    
    Fig 2: Removing Secondary Battery Case From Frame
    Courtesy of FORD MOTOR CO.
Open the battery cable wire retainer located in the front of the primary battery and remove the battery cable.

Fig 3: Removing Battery Cable
Courtesy of FORD MOTOR CO.
Remove the body-to-frame ground bolt.

Fig 4: Removing Body-To-Frame Ground Bolt
Courtesy of FORD MOTOR CO.

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.
  
  Fig 5: Removing Primary Battery Case From Frame
  Courtesy of FORD MOTOR CO.
Remove the primary battery case cover.
- Remove the 2 attaching bolts.
  
  Fig 6: Removing Primary Battery Case Cover
  Courtesy of FORD MOTOR CO.
Remove the secondary battery case cover.
- Remove the 2 attaching bolts.
  
  Fig 7: Removing Secondary Battery Case Cover
  Courtesy of FORD MOTOR CO.
Disconnect the battery cables from the primary and secondary batteries.
Remove the 3 harness locators, along the RH frame rail, and pull the harness through the front body mounting point.

Fig 8: Removing Harness Locators
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Lower the vehicle. For additional information, refer to JACKING & LIFTING .

NOTE: Battery junction box (BJB) cover removed for illustrative purposes.

Fig 11: Removing BJB Battery Cable Nut And Cable End

Courtesy of FORD MOTOR CO.

Remove the BJB battery cable nut and cable end.
Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
Remove the battery cable harness from the wheelwell area.