Photo credit: Ford E250 Wikimedia.org – Public Domain. Photo by IfCar, distributed under a CC-BY 2.0 license.
Hopefully, you’ve found this page because you are looking for battery cables for a Ford Diesel E250, E350 vans the 6.9L, 7.3L, or 6.0L Powerstroke diesel engines.
Table of Contents
The main cables are built from 2/0 (“two-aught”) or optional 3/0 cable for the starter. We use tin-plated (for corrosion resistance) terminals at the battery and standard copper lugs at the engine. To prevent corrosion from the battery’s acidic fumes, we crimp the terminals with a 12-ton hydraulic crimper then seal the connection with adhesive lined heat shrink. Cables are shipped with anti-corrosion battery washers, military-style battery terminals with “Nylox” style locknuts.
We got the dimensions by measuring sets of cables that customers have sent to me over the years. We’ve sold several these however, I suggest you inspect your old cables and make sure these will fit before ordering.
Stock negative cables are 1/0 with #10 gauge chassis grounds. Our negative cables are a heavier 2/0 with #6 gauge chassis grounds. The stock positive cable uses 1/0 for the crossover, 2/0 for the starter, and #6 for the start relay. We use 2/0 for the crossover, 2/0 (optional 3/0) for the starter, and #4 for the fuse block. The heavier gauge wire reduces resistance and might make starting a little easier.
We build our cables using copper lugs crimped to SAE battery cable using a 12-ton hydraulic crimper. Then we seal the connection with adhesive lined heat shrink. Battery washers are included. We make the fuse block and chassis ground wires a little longer than stock since the #4 or #6 wire is not as flexible as the tiny wire the factory uses.
Military Ordinance/Universal Terminals: These terminals allow the customer to add as many electrical accessories as they want. They also have the advantage of being able to replace just the terminals and not the entire cable. We provide a Nylox nut to help you make sure that the bolts remain tight.
Optional 3/0 Starter wire: Customers in cold climates have asked me for a 3/0 starter wire for situations where every little bit helps. It’s now an option when ordering cables. Order the “Cold weather/Hard start option”.
Start relay to starter: Our kit includes the wire that goes from the battery to the starter relay. However, the other wire in the start relay molded rubber connector is optional. If you want to, you can easily reuse your existing wire by cutting the rubber molded connector or cutting the wire and adding crimp on the terminal using normal hand tools. If you prefer to just replace the wire we sell it for your convenience of $6.
Military Terminal Covers: Protect against accident short circuits and damage by using these PVC covers on the terminals. These are included in the price if you buy a full kit.
Convoluted loom: This is the wavy plastic stuff that the factory uses to protects wires from physical abrasion. We’ll add it for $5 per cable or you get it for free when you buy a complete kit.
(Kits will have cables listed, and includes all covers and loom (free loom)
NO FITMENT DATA. MEASURE YOUR CABLES FIRST.
Individual cables if you don’t want to purchase a full kit.
Email for individual prices.
Loom and covers are included in full kits but they are available separately if purchasing individual cable.