Battery, Mounting and Cables: Removal & Installation Ford Econoline E150

Removal

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1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(ref-210181-S12802242912005121400000) .
2. Remove the two 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 three remaining battery case-to-frame bolts. Raise the battery case up and to the right to dislodge the battery case from the three remaining bolts.
5. Lower the auxiliary battery and case until tension is present on the safety straps.
6. Remove the two bolts and disengage the battery case cover.
7. Remove the auxiliary battery cables.
8. Remove the two 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.

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1. Position the auxiliary battery and case on the transmission jack under the vehicle.
2. Install the two safety strap bolts.
3. Install the auxiliary battery cables and the hold-down wedge.
4. Position the cover and install the two 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 three 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 two auxiliary harness-to-frame screws.
8. Enable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(ref-210181-S12802242912005121400000) .

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1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(ref-210181-S12802242912005121400000) .
2. Disconnect the primary battery positive cable, and remove the hold-down wedge and the primary battery.
3. Remove the four 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 three 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 three 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. Follow the removal procedure in reverse order.

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1. Disable the vehicle electrical supply. For additional information, refer to «DUAL BATTERY DISCONNECT»(ref-210181-S12802242912005121400000) .
2. Disconnect the primary battery positive cable, and remove the hold-down wedge and the primary battery (10655). Remove the auxiliary battery.
3. Remove the four bolts retaining the battery tray and remove the battery tray.
4. Remove three rear harness locators, two to the rear of the vacuum reservoir and one 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 three 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).

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1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
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 three remaining battery case-to-frame bolts. Raise the battery case up and to the right to dislodge the battery case from the three 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»(ref-210109) .
15. Remove the BJB battery cable nut and cable end.
16. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
17. Remove the battery cable harness from the wheelwell area.

1. To install, reverse the removal procedure.