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Old 11-29-2018, 03:41 PM   #1
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replacing battery cables

iím having starting issues with my 2004 E350 and based on some other for members help, itís most likely corrosion at the terminal connections. Iíve already pulled the batteries down and clean the terminals once but it looks like I gotta pull the batteries down again because Iím still having issues.

iím now thinking of replacing the battery cables and terminals and making new ones so i donít have to worry about starting up when out in the middle of nowhere.

i remember being under the van when pulling the batteries down last week and seeing the positive and negative come down from the passenger side. where do they disconnect once they head up into the engine block area? what do they connect to? hopefully itís all accessible. i would like to completely remove and use the old ones as template to make new ones. doing it while not being under thevan would be a big plus.
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Old 11-29-2018, 10:37 PM   #2
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Maybe more info about your van is needed. The diesel and gas engines are a bit different. You said "I’ve already pulled the batteries down" so I'm assuming they are frame mounted like a diesel? At least with my 6.0 (IIRC) the cables ran from the starting batteries (on the frame) to a block terminal that has a jump stud then to the starter. You might want to check all the connection points in between. I replaced and upgraded all my stuff some time back so it's a bit different than stock. A single bad starting battery might also cause a similar issue so make sure both starting batteries are up to par. Another thing is if your van has been setup with a battery separator to help jump start the vehicle. At times it might mask an issue with the starting batteries.
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Old 11-30-2018, 04:43 PM   #3
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hi dave, yeah more info would be helpful. it’s a diesel 6.0L. chassis has 225k on it but engine was replaced 82k ago. i’ve had it a few weeks. two batteries in the side rail behind passenger seat. house batterybis in back.

so that’s what i thought. in the block it’s just connected to the jumper terminals and starter. i also do have a separator below the passenger seat. so that would be the only places it’d be connected. so i should be able to completely remove all the cables?

thanks!
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