SVE BULLETIN
SPECIAL VEHICLE ENGINEERING – BODY BUILDERS ADVISORY SERVICE
Toll-free: (877) 840-4338 E-Mail: [email protected] (preferred)
Fax:
(313) 594-2633
Website: www.fleet.ford.com/truckbbas
Date: February 16, 2004
Bulletin Q-102
E-Series Battery Relocation Procedure
To: All Builders Completing/Modifying E-Series Cutaway and Stripped Chassis
Models Affected: All 2004 E-350/450 Cutaway, Chassis Cab, and Stripped Chassis
Note: For gas powered chassis, only the optional aux. battery is frame mounted (carryover
2003 design). The 6.0L Diesel has both batteries frame mounted vs. 2003 7.3L Diesel with one
battery under the hood and one on the frame rail.
Action Requested: Please provide a copy of this bulletin to affected design, production,
purchasing, and service activities.
Background: The 6.0L Diesel E-Series batteries are both located on the passenger-side frame
rail for 2004. Gas powered chassis retain the main battery under hood with the optional aux.
battery frame mounted. Ford recognizes that certain current vehicle applications may require
relocation of the frame mounted battery/batteries. With the increase in battery cable length
associated with the relocation, the relationship of the cable length and gauge becomes more
critical. For example, the 6.0 L diesel engine starter draws up to 850-900 amperes and the
glow plugs draw approximately 270 amperes peak. A small increase in voltage drop due to
increased battery cable length or splice may result in no-start complaints, especially at low
ambient temperatures. While the gas engine aux. battery is not used for starting, issues with
charging can result if precautions similar to those below are not taken.
Description: The following guidelines should be followed when relocating the frame mounted
6.0L Diesel chassis batteries:
• Battery cables should not be spliced. A new, non-spliced, cable should be installed.
Insulation on wiring routed under hood/under body must meet the 125°C temperature
specification of E1107 of the Ford Truck Quality Program Guidebook. (Also see Bulletin
Q-94).
• Appropriate battery hold-down brackets must be used to retain batteries from shifting.
The hold-down system must allow for a minimum 1" (24 mm) air gap between adjacent
batteries.
• The battery ground lug and the red positive jumper cable lug located on the frame must
be relocated to a similar frame position adjacent to the new battery location.
• If the batteries are separated such that a longer cable is required to connect the battery
terminals, this cable must be upgraded from 2 GA to 1 GA or heavier.
Originator: Stephen I. Dains/sdains
Q-102 - Battery Relocation.doc
Page 1 of 2
Date Issued: February 11, 2004
Date Revised: 2/12/2004
•
Use the following chart to determine the proper gauge of cable necessary to assure
proper vehicle starting and charging performance.
6.0 L Diesel Cable Requirements
Desired length of
battery cable
extension (beyond
OEM length)
138" Wheelbase
Desired length of battery
cable extension (beyond
OEM length)
158" & 176" Wheelbase
Cable Required
(Gauge)
Up to 27"
Up to 12"
Up to 39"
Up to 51"
Up to 63"
Up to 24"
Up to 36"
Up to 48"
"00" (Same as
OEM)
"00" + "2" in parallel
"00" + "1" in parallel
"00" + "0" in parallel
Note: Cables in parallel must have appropriate terminals on each end to
assure full current carrying capacity of the pair.
In order to reduce the possibility of environmental conditions resulting in increased starting
voltage drop, all battery cable connection should be coated with a corrosion protectant after all
connections are torqued.
Refer questions on this bulletin to Robert Bradley of the Ford Truck Body Builders Advisory
Service 1-877-840-4338 or [email protected].
Sincerely
D. J. Snyder
Modified Vehicle Engineering Quality Programs
Originator: Stephen I. Dains/sdains
Q-102 - Battery Relocation.doc
Page 2 of 2
Date Issued: February 11, 2004
Date Revised: 2/12/2004