Battery cable routing
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Senior User
Joined: Oct 2007
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From: Good old Oswego.
Battery cable routing
Hey Guys,
I was wondering how the cables on the batteries should be run. This is how they are set up on my truck: Driver side negative going to bottom of driver side engine, positive running over radiator to positive on passenger battery. Then whoever set this up cut away some of the insulation on the positive cable and put a terminal there to connect to the postitive side passenger battery. Then the cable goes down to the starter. The passenger negative cable goes down to the passenger side of the engine at the bottom. Then there is a lead going from the solenoid to the starter. Does this seem right? Is there anything I should do different? Also, what kind of batteries do you guys run?
I was wondering how the cables on the batteries should be run. This is how they are set up on my truck: Driver side negative going to bottom of driver side engine, positive running over radiator to positive on passenger battery. Then whoever set this up cut away some of the insulation on the positive cable and put a terminal there to connect to the postitive side passenger battery. Then the cable goes down to the starter. The passenger negative cable goes down to the passenger side of the engine at the bottom. Then there is a lead going from the solenoid to the starter. Does this seem right? Is there anything I should do different? Also, what kind of batteries do you guys run?
Post Fiend
Joined: Nov 2003
Posts: 21,285
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From: Nutter Fort, WV
The stock setup started at the drivers side positive, then across the radiator support to the passenger side positive, then down to the starter.
At the passenger side positive, there was also an 8 gauge wire out of the positive clamp that went to either the starter solenoid or glow plug relay, depending on the truck year.
The negative leads go down to the lower front of the engine block on both sides, the passenger side has a smaller wire that also connects to the frame.
Batteries should be at least 850 CCA, I am running 1000 CCA's in mine.
The passenger side battery terminal is where the battery cables usually fail first, and since Ford wants 150 dollars for one, someone repaired the one they had.
At the passenger side positive, there was also an 8 gauge wire out of the positive clamp that went to either the starter solenoid or glow plug relay, depending on the truck year.
The negative leads go down to the lower front of the engine block on both sides, the passenger side has a smaller wire that also connects to the frame.
Batteries should be at least 850 CCA, I am running 1000 CCA's in mine.
The passenger side battery terminal is where the battery cables usually fail first, and since Ford wants 150 dollars for one, someone repaired the one they had.
Senior User
Joined: May 2008
Posts: 202
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From: Bentonville, AR
the PO did not want to replace the cable or the terminal connectors. Yet he drove a screw into the small gap between the terminal connector and the terminal. Yeah nice job HUH?
So...I was noot getting a good connection...needless to say. I bought a 27 size battery at Wal-mart, worked fine but not quite enough juice. I was about to order a new positive cable...about $120 and replace it...but I would still need to do the neg side to get some good connection there too.
I went to Batteries Unlimited. They replaced all terminal connectors (cut the old ones back) and I bought a 27R battery (reverse from the pass side). So for the same 120 I have a new batter, new terminals and did not have to crawl around underneath replacing the cable on the starter....really no big deal but easier this way.
They cut back the insulation and found solid copper just beyond where they cut out the old worn out terminals.
Tim
So...I was noot getting a good connection...needless to say. I bought a 27 size battery at Wal-mart, worked fine but not quite enough juice. I was about to order a new positive cable...about $120 and replace it...but I would still need to do the neg side to get some good connection there too.
I went to Batteries Unlimited. They replaced all terminal connectors (cut the old ones back) and I bought a 27R battery (reverse from the pass side). So for the same 120 I have a new batter, new terminals and did not have to crawl around underneath replacing the cable on the starter....really no big deal but easier this way.
They cut back the insulation and found solid copper just beyond where they cut out the old worn out terminals.
Tim
Post Fiend
Joined: Apr 2008
Posts: 5,338
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From: Grants Pass, Oregon
Check out West Marine or another good marine supply store,or a specialty battery store. the factory cables must be either 1/0 or 2/0 gauge cable,you may be able to save some money on cable with welding cable in the same gauge as your existing batt. cables... if your negatives are at least 1 or 2 ga. cable and have good connectors,your probably okay on the ground side.
Elder User
Joined: Aug 2007
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the factory cables are stepped so to speak a very large cable from the starter to the passenger side positive terminal then it steps down to a smaller cable from there to the driver side battery
if i were to replace mine i would use two seperate cables from the batteries to the starter of course they would have to be custom made but more is better here due to amp draw by the starter
if i were to replace mine i would use two seperate cables from the batteries to the starter of course they would have to be custom made but more is better here due to amp draw by the starter
Post Fiend
Joined: Nov 2003
Posts: 21,285
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From: Nutter Fort, WV
Stock cable is 2/0 from the drivers side battery to the passenger side battery.
From the passenger side battery to the starter, the cable is 3/0.
Both of my ground cables are 2/0.
From the passenger side battery to the starter, the cable is 3/0.
Both of my ground cables are 2/0.
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Tuned
Joined: Nov 2002
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From: Benson, AZ
I used 0/1 cable from the starter to bothe patterys with a 2 2ga cables from the passenger battery to the starter relay and the Glowplug relay
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Thread Starter
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Senior User
Joined: Oct 2007
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From: Good old Oswego.
Well I think I found my problem. I believe thatmy cables are junk because they look really bad. Another reason for my conclusion is I've been having starting problems along the lines of the truck starts fine in the morning and once the engine is hot, if I turn it off and try to start it again the starter tuens slow and won't start. If I let the truck sit for a while (hour) and try to start it, it starts right up. At first I thought my batteries were bad but I had them tested and their fine. So I'm gonna replace the cables and connectors. Does it sound about right? Those cables aren't very easy to find are they. I'm having my brother check at the truck shop at work to see if they can get it there.
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 15
From: Nutter Fort, WV
NAPA can make the cables if they have a flag terminal for the passenger side battery terminal.
A very common place for the battery cables to fail is corrosion inside the passenger side cable clamp.
Since all the electrical power on the IDI goes through that connection, it can leave you stranded.
Bad thing, the only way to see it is cut the clamp open.
If the cable looks like it has been hot close to the clamp, my bet is you have corrosion in there.
1/0 and #2 cable is awful small for diesel battery cables.
A very common place for the battery cables to fail is corrosion inside the passenger side cable clamp.
Since all the electrical power on the IDI goes through that connection, it can leave you stranded.
Bad thing, the only way to see it is cut the clamp open.
If the cable looks like it has been hot close to the clamp, my bet is you have corrosion in there.
1/0 and #2 cable is awful small for diesel battery cables.
Thread Starter
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Senior User
Joined: Oct 2007
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From: Good old Oswego.
Someone must have made a new positive cable for my truck before me because the terminal for the passenger side positive is clamped to bare wire where some insulation was cut away. Battery Terminals and Copper Lugs Like the 3-way HD one on this page. I was going to try making a new one like that but better than the one on there now.
Post Fiend
Joined: Nov 2003
Posts: 21,285
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From: Nutter Fort, WV
Actually you need a terminal like this one at the bottom of the page.
BTCF-3/0P
On the side going to the drivers side battery, you can put a #4 wire in with the 2/0 cable to get power to the starter relay or glow plug relay depending on which you truck is using as a power distribution point.
BTCF-3/0P
On the side going to the drivers side battery, you can put a #4 wire in with the 2/0 cable to get power to the starter relay or glow plug relay depending on which you truck is using as a power distribution point.
5th Wheeling
Joined: Apr 2021
Posts: 35
Likes: 1
Reviving old thread it seems.
Have a quick question on my 2000 7.3 Excursion. Someone routed a negative ground cable from my driver side battery to the closest alternator attachment bolt. I assume it used to go down under the engine but was replaced with this cable. Should I be concerned with it there and look to move it to a better location? thanks
Have a quick question on my 2000 7.3 Excursion. Someone routed a negative ground cable from my driver side battery to the closest alternator attachment bolt. I assume it used to go down under the engine but was replaced with this cable. Should I be concerned with it there and look to move it to a better location? thanks
Fleet Mechanic
Joined: Sep 2016
Posts: 1,519
Likes: 224
From: Nevada
You are in the wrong form for your year truck this is for the IDI Pre power Stroke Engines.
You need to check with the guys in the 99 - 03 Power Stroke Engine section.
Things are probably routed differently.
https://www.ford-trucks.com/forums/forum31/
Charlie
You need to check with the guys in the 99 - 03 Power Stroke Engine section.
Things are probably routed differently.
https://www.ford-trucks.com/forums/forum31/
Charlie
Logistics Pro
Joined: Sep 2007
Posts: 3,737
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From: Western Mass
Reviving old thread it seems.
Have a quick question on my 2000 7.3 Excursion. Someone routed a negative ground cable from my driver side battery to the closest alternator attachment bolt. I assume it used to go down under the engine but was replaced with this cable. Should I be concerned with it there and look to move it to a better location? thanks
Have a quick question on my 2000 7.3 Excursion. Someone routed a negative ground cable from my driver side battery to the closest alternator attachment bolt. I assume it used to go down under the engine but was replaced with this cable. Should I be concerned with it there and look to move it to a better location? thanks
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