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2003-2007 Dodge Ram 2500 24V 6.7 Cummins Crossover Cable Replacement

Use this guide to help you fix your 2003-2007...

iFixit Library Dodge ram 2500 Moderate 3 hours Guide 141708

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This attributed iFixit guide is displayed through Fixonic's recorded commercial API permission. iFixit remains the independent source and author of the procedure.

Guide overview

Before you begin

Use this guide to help you fix your 2003-2007 Dodge Ram 2500, 6.7LCummins 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.

Step 1

Repair step

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Be careful while all terminals are still hooked up to each battery. Electrical shock 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.

Step 2

Repair step

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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

Repair step

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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.
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

Repair step

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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

Repair step

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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.
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

Repair step

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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

Repair step

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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).