Battery Terminal

This procedure covers cleaning, inspecting, and replacing battery terminals on the 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Battery terminal ends (positive and negative) × 2 — Top-post or side-post terminals as equipped
• Battery terminal protective spray or felt washers × 1 — Anti-corrosion treatment

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn off all electrical accessories and remove key from ignition
3. Open hood and locate batteries (typically dual batteries on driver side of engine bay)
4. Inspect batteries for damage, leaks, or excessive corrosion before proceeding
5. Have baking soda solution ready to neutralize any acid corrosion encountered

Procedure

1. 1

   Disconnect negative battery terminal first
   Using a 10mm or 13mm wrench (depending on terminal type), loosen the negative (-) battery terminal bolt. Remove the cable from the battery post. If terminal is stuck, use a battery terminal puller—do not pry with screwdriver as this can damage the battery case. Move cable away from battery and secure so it cannot contact the post.
2. 2

   Disconnect positive battery terminal
   Loosen and remove the positive (+) battery terminal bolt. Remove the cable from the battery post using terminal puller if necessary. Keep positive cable separated from negative cable and any ground points.
3. 3

   Inspect and clean battery posts
   Inspect battery posts for damage, excessive corrosion, or wear. Use battery post cleaner tool or wire brush to clean both battery posts until shiny metal is visible. Clean the top of the battery case around posts. Neutralize any corrosion with baking soda solution and rinse with water, avoiding getting solution inside battery.
4. 4

   Inspect cable ends and terminals
   Examine cable ends for fraying, corrosion, or damage. Check terminal clamps for cracks or stripped threads. If terminals are corroded internally or damaged, they must be replaced. Use wire brush or terminal cleaning tool to clean inside of terminal clamps until bright metal is visible.
5. 5

   Replace terminals if necessary
   If replacing terminals, cut off old terminals leaving enough cable length for new connection. Strip cable insulation back approximately 1/2 inch. For crimp-type terminals, crimp securely using proper crimping tool. For bolt-on terminals, ensure all strands are captured and bolt is properly seated before tightening.
6. 6

   Install positive terminal first
   Place positive terminal onto positive battery post, ensuring full contact and proper seating. Install terminal bolt and tighten to specification (approximately 11-15 Nm / 8-11 ft-lbs) using torque wrench. Terminal should be snug but not deformed from over-tightening.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
7. 7

   Install negative terminal
   Place negative terminal onto negative battery post, ensuring full contact and proper seating. Install terminal bolt and tighten to specification using torque wrench. Verify terminal cannot be rotated by hand after tightening.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
8. 8

   Verify ground connections
   Inspect engine block ground strap and chassis ground connections. Remove, clean contact surfaces with wire brush, and reinstall ground connections if corrosion is present. Ensure metal-to-metal contact at all ground points.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)

   Ground Cable Bolt14 Nm (10 lb-ft)
9. 9

   Apply corrosion protection
   Apply thin coat of dielectric grease or anti-corrosion spray to battery terminals and exposed cable connections. Alternatively, install felt corrosion washers under terminals. Do not apply excessive grease as this can attract dirt.

Reassembly

1. Verify all terminal connections are tight and properly torqued
2. Ensure no tools or debris are left in engine bay
3. Confirm battery hold-down is secure if it was loosened during service

Verification

• Turn key to ON position and verify instrument cluster illuminates normally
• Start engine and verify normal cranking and starting operation
• Check that alternator is charging (voltmeter should show 13.5-14.5V with engine running)
• Verify all electrical accessories function properly (lights, radio, windows, etc.)
• Inspect terminals after first drive for any signs of looseness or heating
• Reset clock and radio presets as needed

Related trouble codes on this vehicle

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