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Battery, Mounting and Cables Ford Cutaway E350

Charging System 40 illustrations ~1510 words

GENERAL SPECIFICATIONS

ItemSpecification
4.6L, 5.4L, 6.8L
Voltage12 volts
Cold cranking amps (CCA)650 CCA (625 CCA on auxiliary battery)
Amp/hr72 amp/hr (75 amp/hr on auxiliary battery)
6.0L
Voltage12 volts
Cold cranking amps (CCA)750 CCA
Amp/hr78 amp/hr

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Auxiliary battery case to frame bolts34 - 46
Auxiliary battery ground cable-to-frame bolt12 - 15
Auxiliary battery harness-to-frame clip screws12 - 15
Auxiliary battery relay mounting screws7 - 9
Auxiliary battery relay terminal nuts7 - 9
Auxiliary or battery hold-down wedge screw5.5 - 7
Auxiliary or battery safety strap bolts26 - 34
Auxiliary case cover bolts6 - 7
Auxiliary positive and negative battery terminal nuts13 - 17
Battery box cover bolts7
Battery junction box (BJB) cable nut8
Battery negative cable body ground screw (6.0L)30
Battery negative cable-to-frame bolt (6.0L)25
Battery positive cable bracket nut (6.0L)30
Battery tray bolts22 - 34
Body-to-frame ground bolt9
Primary battery cable bracket nut, 4.6L7 - 9
Primary battery cable bracket nut, 5.4L and 6.8L26 - 34
Primary battery cable ground eyelet nut7 - 9
Primary positive and negative battery terminal nuts6 - 8
Primary positive and negative battery terminal nuts13 - 17
Radiator support bracket bolts (6.0L)14
Starter cable hanger stud nut20
Starter motor positive terminal nut (6.0L)5
Starter motor relay B+ and enable terminal nuts7 - 9
Starter motor relay mounting screws7 - 9
Starter motor/solenoid B+ terminal nut11 - 13
Starter motor/solenoid enable terminal nut4 - 6
Starter motor/solenoid ground nut20 - 25
Starter motor/solenoid ground stud22 - 28
Starter motor/solenoid mounting bolts22 - 28
Starter solenoid cable nut (6.0L)3
Jump-start connection bracket bolts (6.0L)20

TORQUE SPECIFICATIONS

4.6L, 5.4L, 6.8L engine

A primary 72 ampere-hour, maintenance-free battery, mounted in the forward right-hand side of the engine compartment, is standard.

The primary battery system consists of the following components

  1. primary battery
  2. battery cables
  3. primary battery case

The auxiliary battery option includes a remotely packaged auxiliary 75 ampere-hour, serviceable, deep cycle battery. The auxiliary battery is located on the right-hand frame rail to the rear of the B-pillar. The auxiliary battery is used to supply the trailer circuits with power when the vehicle is not running. The auxiliary battery is connected in parallel with the primary battery through the auxiliary battery relay when the engine is running. The auxiliary battery uses the same primary cable as the primary battery.

6.0L engine

Two 78 ampere-hour, maintenance-free batteries are mounted on the right hand frame rail.

The diesel battery system consists of the following components

  1. primary battery
  2. secondary battery
  3. battery cables
  4. battery cases

Scheme 1

Scheme 1: Environmental Protection
Scheme 1: Environmental Protection

Special Tool(s)

SPECIAL TOOL Micro 490 Digital Battery Analyzer 162-00004 or equivalent

Scheme 2

Scheme 2: Special Tool(s)
Scheme 2: Special Tool(s)

Inspection and Verification

  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Battery Battery mounting Battery cables Battery posts
  3. If an obvious cause for a concern is found, correct the cause before proceeding to the next step.
  4. If the fault is not visually evident, proceed to the pinpoint test.

PINPOINT TEST A: BATTERY CONDITION TEST

  1. A1 TEST THE BATTERY CONDITION NOTE: No battery with a red test-eye should be replaced. The red eye only means the battery is discharged, not necessarily defective. NOTE: Failure to fully charge the battery before retesting may cause false readings. Verify the battery condition using the Battery Analyzer. Is the battery OK? Yes : If the meter reads GOOD BATTERY, RETURN the battery to service. REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . If the meter reads GOOD-RECHARGE, CHARGE the battery and RETURN it to service. REFER to «CHARGING SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . If the meter reads CHARGE & RETEST, fully CHARGE and RETEST the battery. No : If the meter reads REPLACE BATTERY, INSTALL a new battery. REFER to «BATTERY - AUXILIARY»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . If the meter reads BAD CELL-REPLACE, INSTALL a new battery. REFER to «BATTERY - AUXILIARY»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

Scheme 3

Scheme 3: Disconnect - Vehicles with 4.6L, 5.4L and 6.8L engine
Scheme 3: Disconnect - Vehicles with 4.6L, 5.4L and 6.8L engine

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Disconnect the primary battery ground cable.
  2. Disconnect the auxiliary battery frame ground. Remove the ground bolt. Pull the cable away from the frame and make sure the cable does not contact the frame.

Scheme 6

Scheme 6: Connect - Vehicles with 4.6L, 5.4L and 6.8L engine
Scheme 6: Connect - Vehicles with 4.6L, 5.4L and 6.8L engine

Scheme 7

Scheme 7
Scheme 7
  1. Reconnect the auxiliary battery frame ground.
  2. Reconnect the primary battery ground cable.

Scheme 8

Scheme 8: Disconnect - Vehicles with 6.0L engine
Scheme 8: Disconnect - Vehicles with 6.0L engine
CAUTIONIf equipped with the CD6 audio unit, precautions must be taken when the battery has been disconnected. When reconnecting the battery, make sure no interruption of power occurs for 30 seconds. If power is interrupted during the first 30 seconds, permanent damage to the CD6 audio unit will result.
  1. Disconnect the secondary battery ground cable.

Scheme 9

Scheme 9: Connect - Vehicles with 6.0L engine
Scheme 9: Connect - Vehicles with 6.0L engine
  1. Reconnect the secondary battery ground cable.

Battery Disconnect

WARNINGBatteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNINGTo avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before repairing, installing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Failure to follow these instructions may result in personal injury. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury.
WARNINGWhen lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
WARNINGKeep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
CAUTIONIf equipped with the CD6 audio unit, precautions must be taken when the battery has been disconnected. When reconnecting the battery, make sure no interruption of power occurs for 30 seconds. If power is interrupted during the first 30 seconds, permanent damage to the CD6 audio unit will result.
  1. Disconnect the battery ground cable.
  2. Disconnect the positive battery cable.
  3. To install, reverse the removal procedure.

Removal

WARNINGBatteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNINGKeep body from under the auxiliary or secondary battery when disconnecting or reconnecting the auxiliary battery safety straps since the battery weighs 50 pounds and bodily injury can result. Failure to follow these instructions may result in personal injury.

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Scheme 16
  1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Remove the 2 auxiliary battery cable harness screws retaining the harness to the frame.
  3. Support the bottom of the auxiliary battery and case with a transmission jack.
  4. Remove the auxiliary battery case from the frame. Remove the upper RH auxiliary case-to-frame bolt. Loosen, but do not remove, the 3 remaining battery case-to-frame bolts. Raise the battery case up and to the right to dislodge the battery case from the 3 remaining bolts.
  5. Lower the auxiliary battery and case until tension is present on the safety straps.
  6. Remove the 2 bolts and disengage the battery case cover.
  7. Remove the auxiliary battery cables.
  8. Remove the 2 auxiliary battery case safety strap to frame bolts.
  9. Remove the hold-down wedge.
  10. Support the battery and case with a transmission jack. Disengage the safety straps and roll the auxiliary battery and case on the transmission jack away from the vehicle.

Scheme 17

Scheme 17: Installation
Scheme 17: Installation

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Scheme 22
Scheme 22
  1. Position the auxiliary battery and case on the transmission jack under the vehicle.
  2. Install the 2 safety strap bolts.
  3. Install the auxiliary battery cables and the hold-down wedge.
  4. Position the cover and install the 2 auxiliary battery case cover bolts.
  5. Lift the battery and case in position for connecting the safety straps.
  6. Install the auxiliary battery case to the frame. Align the slots in the battery case to the frame, using 3 bolts. (Do not tighten.) Move the battery case slightly toward the frame and lower into position. Install the remaining battery case-to-frame bolt and tighten all bolts to specification.
  7. Install the 2 auxiliary harness-to-frame screws.
  8. Enable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

Scheme 23

Scheme 23: Removal
Scheme 23: Removal

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Scheme 28
Scheme 28
  1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Disconnect the primary battery positive cable, and remove the hold-down wedge and the primary battery.
  3. Remove the 4 bolts retaining the battery tray and remove the battery tray.
  4. Remove the primary battery negative cable ground nut and disengage the eyelet terminal.
  5. Remove the starter motor relay B+ terminal rubber cap.
  6. Remove the starter motor relay eyelet terminals. Remove the B+ terminal nut and disengage the wire. Remove the enable terminal nut and disengage the wire.
  7. Remove the 3 harness locators in between the primary battery tray mounts.
  8. Remove the starter motor/solenoid eyelet terminals. Remove the B+ terminal nut and disengage the wire. Remove the enable nut and disengage the wire. Remove the ground nut and disengage the wire.
  9. Disengage the 3 engine splash shield plastic clips and remove the engine splash shield.
  10. Remove the transmission cooler line/primary battery cable bracket nut.
  11. Pull the primary battery cable assembly through the engine support crossmember under the vehicle.
  12. Disengage the harness locator, located below the battery tray mounts.
  13. Pull the primary battery cable assembly out of the vehicle from the engine compartment.

Installation

  1. To install, reverse the removal procedure.

Scheme 29

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Scheme 29

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Scheme 30
Scheme 30

Scheme 31

Scheme 31: Removal
Scheme 31: Removal

Scheme 32

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Scheme 34
Scheme 34
  1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Disconnect the primary battery positive cable, and remove the hold-down wedge and the primary battery. Remove the auxiliary battery.
  3. Remove the 4 bolts retaining the battery tray and remove the battery tray.
  4. Remove 3 rear harness locators, 2 to the rear of the vacuum reservoir and 1 to the front of the vacuum reservoir, along the RH frame rail.
  5. Pull the harness through the vacuum reservoir and the frame.
  6. Remove 3 front harness locators, along the RH frame rail, and pull the harness through the front body mounting point.
  7. Remove the engine compartment harness locator.
  8. Remove the nut and disengage the harness eyelet.
  9. Pull the harness out from the engine compartment.
  1. To install, reverse the removal procedure.

Note. This procedure covers the removal of the battery cables and the batteries. Perform only the steps necessary to remove the appropriate part(s).

Scheme 35

Scheme 35: Removal
Scheme 35: Removal

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Scheme 40
  1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Disconnect the jump-start connection by removing the 2 jump-start connection bracket bolts.
  3. Open the battery cable wire retainer between the secondary and primary batteries to remove the battery cables.
  4. Remove the secondary battery case from the frame. Remove the RH secondary case-to-frame bolt. Loosen, but do remove, the 3 remaining battery case-to-frame bolts. Raise the battery case up and to the right to dislodge the battery case from the 3 remaining bolts. Lower the battery case until it rests on the safety straps.
  5. Open the battery cable wire retainer located in the front of the primary battery and remove the battery cable.
  6. Remove the body-to-frame ground bolt.
  7. Remove the primary battery case from the frame. Remove the RH primary case-to-frame bolt. Loosen, but do remove, the 3 remaining battery case-to-frame bolts. Raise the battery case up and to the right to dislodge the battery case from the 3 remaining bolts.
  8. Remove the primary battery case cover. Remove the 2 attaching bolts.
  9. Remove the secondary battery case cover. Remove the 2 attaching bolts.
  10. Disconnect the battery cables from the primary and secondary batteries.
  11. Remove the 3 harness locators, along the RH frame rail, and pull the harness through the front body mounting point.
  12. Remove the 2 harness locators in front of the front body mounting point.
  13. Remove the starter solenoid wiring. Remove the protective cap. Remove the solenoid enable terminal nut. Remove the solenoid enable cable end. Remove the solenoid B+ terminal nut. Remove the solenoid B+ cable end. Remove the starter cable hanger stud nut. Remove the starter cable hanger.
  14. Lower the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  15. Remove the BJB battery cable nut and cable end.
  16. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  17. Remove the battery cable harness from the wheelwell area.
  1. To install, reverse the removal procedure.

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