Battery Cable: Service and Repair

Battery Cables - Diesel









Removal and Installation

All battery cables

1. Disconnect the battery. For additional information, refer to Battery Disconnect - Dual Battery Disconnect - Dual.

Negative battery cable

2. Remove the screw and position the battery ground cable terminal aside.
- To install, tighten to 9 Nm (80 lb-in).

3. Remove the bolt and position the battery ground cable terminal aside.
- To install, tighten to 62 Nm (46 lb-ft).

4. NOTE: Position the RH splash shield aside to access the battery ground cable bolt.

Remove the bolt and position the battery ground cable-to-frame terminal aside.

- To install, tighten to 30 Nm (22 lb-ft).

Auxiliary negative battery cable

5. NOTE: Position the LH splash shield aside to access the battery ground cable bolt.

Remove the bolt and position the auxiliary battery ground cable-to-frame terminal aside.

- To install, tighten to 40 Nm (30 lb-ft).

Positive battery cable

6. Remove the starter solenoid terminal cover.

7. Remove the nut and position the starter solenoid positive cable terminal aside.
- To install, tighten to 12 Nm (106 lb-in).

8. Remove the nut and position the starter solenoid wire terminal aside.
- To install, tighten to 5 Nm (44 lb-in).

9. Remove the nut from the stud and remove the positive battery cable bracket from the stud.
- To install, tighten to 25 Nm (18 lb-ft).

10. Remove the bolt and position the positive battery cable-to-frame bracket aside.
- To install, tighten to 30 Nm (22 lb-ft).

11. Remove the positive cable terminal nut(s) and position the attaching cable terminal(s) aside.
- To install, tighten to 9 Nm (80 lb-in).

12. Disconnect the starter relay electrical connector.

Auxiliary positive battery cable

13. Remove the 5 pin-type retainers and the upper radiator air deflector.

14. Remove the nut and position the Power Distribution Box (PDB) cable terminal aside.
- To install, tighten to 9 Nm (80 lb-in).

15. Release the positive battery cable locators and remove the cable.

16. To install, reverse the removal procedure.
- A clearance of at least 15 mm (0.59 in) must be kept between the positive battery cable and the splash shield bolt. To verify there is sufficient clearance, place hand between the positive battery cable and splash shield bolt. If unable to fit hand between the splash shield bolt and positive battery cable, bend the P-clip over the frame and recheck clearance.