How to repair broken positive battery cable on 2004 E350 6.0

[coolfeet]

I was inspected my 2 frame rail mounted batteries and noticed the positive battery cable connector to the battery post is broke.

It's not as simple as installing a new end as this is a spliced flag style batter connection. It connects the first battery positive to rear battery positive.

Has anyone experienced this break? A brand new cable is $660 on Ebay. I have a quote for $200 to repair it.

See attached photo. Ford does some stupid engineering that saves money for them and makes repairs hard for us.

[SixCardCharlie]

My negative terminal was on the verge of doing that on one of my batteries. It was also super corroded
I took the cables off and took it into an electricians shop and had them make me a new one. It was way cheaper.

You can go even cheaper if you are willing to tackle the job yourself.

[carringb]

Buy 1 battery cable terminal, flag style and two matching solder pellets, finish with some high-shrink ratio heavy wall heat shrink. It will costs under $25 if you DIY.

http://www.napaonline.com/Catalog/Ca...338_0282439994

http://www.napaonline.com/Catalog/Ca...265_0218261389

http://www.napaonline.com/Catalog/Ca...129_0063685669

I've done hundreds of battery terminal repairs using that methods. It's as good, if not better than OEM.

[coolfeet]

Originally Posted by carringb

Buy 1 battery cable terminal, flag style and two matching solder pellets, finish with some high-shrink ratio heavy wall heat shrink. It will costs under $25 if you DIY.

http://www.napaonline.com/Catalog/Ca...338_0282439994

http://www.napaonline.com/Catalog/Ca...265_0218261389

http://www.napaonline.com/Catalog/Ca...129_0063685669

I've done hundreds of battery terminal repairs using that methods. It's as good, if not better than OEM.

Thanks.

The connection on the right has the starter connected and one other connection. Can I get a flag style with 2 connections?

[carringb]

I haven't seen them with a two connections on one side (doesn't mean they don't have them). However, they do make them with mis-matched ends, so going up a size on the double cable end should accommodate both cables, but you might want a helper pushing both cables into the molten solder.

[coolfeet]

Originally Posted by carringb

I haven't seen them with a two connections on one side (doesn't mean they don't have them). However, they do make them with mis-matched ends, so going up a size on the double cable end should accommodate both cables, but you might want a helper pushing both cables into the molten solder.

I think I can leave the broken connection in and add a flag connector to the left. It will be easier. Need to wrap the broken terminal.