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Battery Cable Replacement

Old Feb 17, 2026 | 08:09 AM
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Battery Cable Replacement

Have an 02 and it’s time for cables. Truck is starting weak/running out of eletric. Batteries are fresh. Then once turned in no issues.

Planning on 2/0 tinned copper wire, lugs and military terminals. Is it worth using 3/0 to the starter?

passenger side negative has a small ground wire coming off the main crimp. Thinking I’ll make a separate cable to replace that one not a fan of crimping 2 wires in one lug on acct the heat shrink dosent come out as good.

Has anyone done an 02? Seems ~4/5 connections come off the passenger side positive. Any advice or photos would be great.

thanks
 
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Old Feb 17, 2026 | 08:30 AM
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I don't think it's worth going out of your way to buy a piece of 3/0; just stick with 2/0.

I have an 03 and there are several cables on the passenger side as well as a couple added ones

From memory..there is starter, crossover to drivers, alternator and power to glow plug/ air intake heater relays iirc
 

Last edited by INFRNL; Feb 17, 2026 at 08:35 AM.
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Old Feb 17, 2026 | 09:26 AM
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If you don't already have the tools to crimp your own cables, I highly recommend CE Auto Electric's kit.
 
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Old Feb 17, 2026 | 03:05 PM
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If you're gonna diy, go for the overkill. I went 4/0 extreme because I couldn't think of a reason not to.
https://www.batterycablesusa.com/ext...ery-cable-bulk

I will say it is not for tight bends.
 
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Old Feb 18, 2026 | 05:35 AM
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I will recommend welding cable, finer wires inside so very flexible, and is rated at a higher amperage

 
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Old Feb 18, 2026 | 07:07 AM
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Originally Posted by MDHunter
I will recommend welding cable, finer wires inside so very flexible, and is rated at a higher amperage
I wholeheartedly agree with this recommendation. I used to buy spools of it when I had the shop for building my own cables for whatever. Very flexible makes it easy to route without struggling to bend the cable to fit the area.
 
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Old Feb 18, 2026 | 07:26 AM
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Also, don’t forget to consider the starter as part of the equation.

i installed the Power Master 9051. All new 2/0 welding cable (my wheelhouse).

here’s my ‘02:



















several things worth noting:

the hand held hydraulic crimper with dies are very inexpensive (I use mine all the time.

in my opinion, use closed lugs not what FORD did with open lugs (see picture and oxidation going leeching into the copper strands on the OEM cable

use marine heat shrink, it has a glue inside the shrink tube to seal it

do a test run with the dies, do not over crimp, it can break the copper strands

welding cable is best practice (that’s my trade)

also don’t forget the crossover positive cable

and don’t forget all of the grounds (motor,frame)

and if you do look at power master starters look at certified dealers, not Amazon or EBay…… there are counterfeits.

Big Horn 2
 

Last edited by Big Horn 2; Feb 18, 2026 at 09:18 AM.
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Old Feb 20, 2026 | 07:00 PM
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Thanks for the replies going to start tomorrow. This is a great chance to spend more money building it than buying it lol. At least it will be full tinned copper all around including wire. Should easily last 20 plus years.

thats a nice battery cut off may add one as when the trucks parked I’m not a fan leaving it plugged in 24/7 to a maintainer. Routinely run equipment that has sat generally if the battery was shut off it’s good to go.
 

Last edited by RigCity; Feb 20, 2026 at 07:03 PM.
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Old Feb 22, 2026 | 05:26 AM
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Originally Posted by RigCity
Thanks for the replies going to start tomorrow. This is a great chance to spend more money building it than buying it lol. At least it will be full tinned copper all around including wire. Should easily last 20 plus years.

thats a nice battery cut off may add one as when the trucks parked I’m not a fan leaving it plugged in 24/7 to a maintainer. Routinely run equipment that has sat generally if the battery was shut off it’s good to go.

RigCity, a battery cut off can be a good idea, especially if there’s nowhere to plug in a battery maintainer. However, in my photo that is a Blue Seas 600A cut off switch for my 17,500# winch power going to the front bumper. I wanted to be able to isolate the power to it in case of a front collision when the winch is not in use👍

I also use the Anderson style plug for other things as well and have an ANL fuse holder where I can swap out different amp fuses.

i should have specified in my original photo. Enjoy your upcoming project🙂

 
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Old Feb 22, 2026 | 10:12 AM
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Originally Posted by Big Horn 2
Blue Seas 600A cut off switch
They make awesome stuff, don't they? I have one of their remote cutoff switches and fuse holder in my trailer.


 
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Old Feb 22, 2026 | 12:27 PM
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Yes they do👍
 
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Old Feb 22, 2026 | 02:49 PM
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I used these cables about 6 years ago on my 2001 F350 i used to have. I am definitely not as electrically inclined as the people responding, but i personally went to this guys shop when i bought them seeing as I lived in Mesa and was about 10 minutes away. I was planning on using the same kit gain when i change them on my 2002 eventually. They were extremely thick and i coupled this with the Green Sticker Denso starter and my 2001 always started regardless of weather. I believe i started it in -12 degrees without it being plugged in.

Ford - Super Duty F250 F350 Excursion Power Stroke 7.3L, 1999-2003 3/0 (Hard Start Kit) #2300 - Custom Battery Cables
 
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Old Feb 22, 2026 | 02:58 PM
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wow, got a dealer just 30 miles from me

West Marine
4317-A South Sheridan Rd
Tulsa, OK 74145
(918) 665-2101
www.westmarine.com
 
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