2003 2007 Dodge Ram 2500 24V 5 9L Cummins Crossover Cable Replacement 2003 2004 2005 2006 2007 Repair Guide

Difficulty

Moderate

Steps

Time Required

                          3 hours

Sections

Crossover Cable
7 steps

Flags

Back2003-2007 Dodge Ram 2500 24V 5.9L Cummins
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Introduction

We will be dealing with issues related to crossover cable and understanding how overheating affects the passenger side battery due to corrosion.

The repair will also include creating a new cable (if needed) in case of scarcity of the replacement product for the engine.

What you need

Step 1

              Crossover Cable

Be careful while all terminals are still hooked up to each battery. Electrical shot and bodily harm can be avoided using caution and gloves during removal. Inspect terminals, cables, and connections for corrosion and burn markings.
Remove the nuts and cables from each battery terminal on both batteries.
Remove the positive terminals from both the driver and passenger batteries.
Remove the negative terminals from each of the driver and passenger batteries.
Remove the crossover cable connected to both positive terminals and unclip them from the upper radiator support bar.

Be careful while all terminals are still hooked up to each battery. Electrical shot and bodily harm can be avoided using caution and gloves during removal. Inspect terminals, cables, and connections for corrosion and burn markings.

Remove the nuts and cables from each battery terminal on both batteries.

Remove the positive terminals from both the driver and passenger batteries.

Remove the negative terminals from each of the driver and passenger batteries.

Remove the crossover cable connected to both positive terminals and unclip them from the upper radiator support bar.

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Step 2

Unroll and straighten the cable to measure the length correctly.
Measure the cable to 88 inches using the tape measure and mark it.
Using the heavy cable cutters, cut the cable lining the edges with the marking.
Be extremely careful when using the cutters to avoid any bodily harm.

Unroll and straighten the cable to measure the length correctly.

Measure the cable to 88 inches using the tape measure and mark it.

Using the heavy cable cutters, cut the cable lining the edges with the marking.

Be extremely careful when using the cutters to avoid any bodily harm.

Step 3

Put the lug and cable parallel to determine how much coating to strip away from the cable. Align the end of the cable to the end where the cable would bottom out of the cable lug.
After finding the appropriate length, mark the cable at the end of the lug.
Use a razor blade to cut only through the rubber layer around the circumference. Make sure to cut through the outer coating to the copper wires.
To remove the layer, pull and twist the coating away from the rest of the cable; it will make a tighter wire to avoid strands from fraying.
When using a razor or X-Acto knife, be careful of the blades as they are incredibly sharp. If you are not comfortable using a razor, use cable strippers.

Put the lug and cable parallel to determine how much coating to strip away from the cable. Align the end of the cable to the end where the cable would bottom out of the cable lug.

After finding the appropriate length, mark the cable at the end of the lug.

Use a razor blade to cut only through the rubber layer around the circumference. Make sure to cut through the outer coating to the copper wires.

To remove the layer, pull and twist the coating away from the rest of the cable; it will make a tighter wire to avoid strands from fraying.

When using a razor or X-Acto knife, be careful of the blades as they are incredibly sharp. If you are not comfortable using a razor, use cable strippers.

Step 4

After removing the coating, insert the exposed cable into the lug.
Measure how much shrink wrap you will need to encase the cable lug. Extend past the cut by an inch to protect the connection from corrosion.
Encase the wire with the cut shrink wrap and more it beyond the lug

After removing the coating, insert the exposed cable into the lug.

Measure how much shrink wrap you will need to encase the cable lug. Extend past the cut by an inch to protect the connection from corrosion.

Encase the wire with the cut shrink wrap and more it beyond the lug

Step 5

Using the hammer cable crimper, align the punch at the end of the lug. This will help keep the cable from pushing out of the lug. Using a hammer, hit the top of the punch until the cable is fully crimped.
Align the punch with the front of the lug after completing the first crimp. Using the hammer, hit the top of the punch until the cable is fully crimped.
When hitting the punch with the hammer, be careful to avoid hitting any fingers.
If the wire and the lug are fully crimped there should be no movement between the cable and lug. The lug should not be able to slide off of the cable.

Using the hammer cable crimper, align the punch at the end of the lug. This will help keep the cable from pushing out of the lug. Using a hammer, hit the top of the punch until the cable is fully crimped.

Align the punch with the front of the lug after completing the first crimp. Using the hammer, hit the top of the punch until the cable is fully crimped.

When hitting the punch with the hammer, be careful to avoid hitting any fingers.

If the wire and the lug are fully crimped there should be no movement between the cable and lug. The lug should not be able to slide off of the cable.

Step 6

Slide the shrink wrap over the connection to cover it.
Using a heat gun, heat the shrink wrap until all the shrink wrap around the cable is taut.
Be mindful to not touch any parts while heating and proceed to the next step after the shrink wrap cools.

Slide the shrink wrap over the connection to cover it.

Using a heat gun, heat the shrink wrap until all the shrink wrap around the cable is taut.

Be mindful to not touch any parts while heating and proceed to the next step after the shrink wrap cools.

Step 7

After completion of the new crossover cable, complete step 1 in reverse.
Take all precautions from the first step while conducting the steps in reverse.
When hooking the battery terminals back up to the batteries, make sure to connect the negative (black cable) terminal before the positive (red cable).

After completion of the new crossover cable, complete step 1 in reverse.

Take all precautions from the first step while conducting the steps in reverse.

When hooking the battery terminals back up to the batteries, make sure to connect the negative (black cable) terminal before the positive (red cable).

To install the new cable, follow the first step in reverse order.

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Author

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                    Dillon LeMire

Member since: 02/01/2021

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                       Embry-Riddle Aeronautical University, Team S7-G15, Rauch Spring 2021                        

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