Voltage Drop Test

The voltage drop test will determine if there is excessive resistance in the battery terminal connections or the battery cables. When performing these tests, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached.

Example: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable clamp and the cable connector at the starter solenoid. If you probe the battery positive terminal post and the cable connector at the starter solenoid, you are reading the combined voltage drop in the battery positive cable clamp-to-terminal post connection and the battery positive cable.

WARNING:
- IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
- EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
- THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CON- TACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.
- IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS.

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing the tests, be certain the following procedures are accomplished:

WARNING: MODELS EQUIPPED WITH THE DIESEL ENGINE OPTION ALSO HAVE AN AUTOMATIC SHUTDOWN (ASD) RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). HOWEVER, REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO UNPLUG THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY.

- Battery is fully-charged. See Battery in the Diagnosis and Testing for more information.
- Fully engage the parking brake.
- If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and fully depress the clutch pedal.

Fuel Shutdown Solenoid Connector - Diesel Engine:

- Unplug the Automatic ShutDown (ASD) relay to prevent a gasoline engine from starting. The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC label for ASD relay identification and location. To prevent a diesel engine from starting, unplug the fuel shutdown solenoid wire harness connector.

Test Battery Negative Connection Resistance - Typical:

1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and the terminal post.

Test Battery Positive Connection Resistance - Typical:

2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable damp and the terminal post.

Test Battery Positive Cable Resistance - Typical:

3. Connect the voltmeter to measure between the battery positive terminal post and the starter solenoid battery terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery cable connection at the solenoid. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable.

Test Ground Circuit Resistance - Typical:

4. Connect the voltmeter to measure between the battery negative terminal post and a good clean ground on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable attachment on the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.