Auxiliary Battery

BATTERY - AUXILIARY

REMOVAL

WARNING:
- Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
- Keep body from under the auxiliary or secondary battery when disconnecting or reconnecting the auxiliary battery safety straps since the battery weighs 50 pounds and bodily injury can result. Failure to follow these instructions may result in personal injury.

1. CAUTION: Failure to accurately follow the battery disconnect procedures may result in vehicle or component damage.

NOTE:
- The preferred method of service requires the use of a floor hoist to lift the vehicle overhead, and a transmission jack to support and lower the auxiliary battery case.
- The auxiliary battery can be charged while the auxiliary battery safety straps are connected to the vehicle. Follow the procedures up to and including disconnection of the auxiliary battery cables.

Disable the vehicle electrical supply.







2. Remove the two auxiliary battery cable harness screws retaining the harness to the frame.
3. Support the bottom of the auxiliary battery and case with a transmission jack.







4. CAUTION: To prevent possible damage to the auxiliary battery case, cover the battery cables during the lowering process. It is recommended to loosen the auxiliary battery case cover bolts before lowering the battery box.

Remove the auxiliary battery case from the frame.
1 Remove the upper RH auxiliary case-to-frame bolt.
2 Loosen, but do not remove, the three remaining battery case-to-frame bolts.
3 Raise the battery case up and to the right to dislodge the battery case from the three remaining bolts.












5. Lower the auxiliary battery and case until tension is present on the safety straps.












6. Remove the two bolts and disengage the battery case cover.
7. Remove the auxiliary battery cables.







8. Remove the two auxiliary battery case safety strap to frame bolts.
9. Remove the hold-down wedge.

10. WARNING: When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.

Support the battery and case with a transmission jack. Disengage the safety straps and roll the auxiliary battery and case on the transmission jack away from the vehicle.

INSTALLATION

1. WARNING: When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.

Position the auxiliary battery and case on the transmission jack under the vehicle.







2. Install the two safety strap bolts.








3. Install the auxiliary battery cables and the hold-down wedge.












4. Position the cover and install the two auxiliary battery case cover bolts.
5. Lift the battery and case in position for connecting the safety straps.







6. Install the auxiliary battery case to the frame.
1 Align the slots in the battery case to the frame, using three bolts. (Do not tighten.)
2 Move the battery case slightly toward the frame and lower into position.
3 Install the remaining battery case-to-frame bolt and tighten all bolts to specification.







7. Install the two auxiliary harness-to-frame screws.

8. CAUTION: Failure to accurately follow the battery connect procedures may result in vehicle or component damage.

NOTE: When the battery is disconnected and connected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn the strategy.

Enable the vehicle electrical supply.