Introduction
Use this guide to help you fix your 2003-2007 Dodge Ram 2500, 5.9L Cummins Diesel battery charging problems. The battery is commonly used by various car brands like Ford, Lincoln, and Dodge.
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
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Remove the nuts and cables from each battery terminal on both batteries.
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Remove the positive terminals from both the driver and passenger batteries.
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Remove the negative terminals from each of the driver and passenger batteries.
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Remove the crossover cable connected to both positive terminals and unclip them from the upper radiator support bar.
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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.
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After finding the appropriate length, mark the cable at the end of the lug.
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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.
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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.
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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.
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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.
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To install the new cable, follow the first step in reverse order.
To install the new cable, follow the first step in reverse order.