Ford Falcon. Manual — part 351

414-01-3

Battery, Mounting and Cables

414-01-3

DESCRIPTION AND OPERATION

Battery and Cables

Vehicles are equipped with a 12 volt

maintenance-free battery.
The battery and cable system consists of the following

components:

battery
battery cable assembly
battery tray

Ford Motor Company strongly recommends that

lead-acid batteries be returned to an authorized

recycling facility for disposal.

WARNING: Keep out of the reach of children.

Batteries contain sulfuric acid. Avoid contact with

skin, eyes, or clothing. Also, shield your eyes

when working near batteries to protect against

possible splashing of the acid solution. In case of

acid contact with skin or eyes, flush immediately

with water for a minimum of 15 minutes and get

prompt medical attention. If acid is swallowed, call

a physician immediately. Failure to follow these

instructions may result in personal injury.

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.

WARNING: When lifting a plastic-cased

battery, excessive pressure on the end walls

could cause acid to spew through the vent caps

resulting in personal injury or damage to the

vehicle or to the battery. Lift with a battery carrier

or with your hands on opposite corners.

WARNING: To avoid accidental deployment

and possible injury, the backup power supply

must be depleted before repairing or installing

any front or side air bag supplemental restraint

system (SRS) components and before repairing,

installing, adjusting or striking components near

the front or side air bag sensors, such as doors,

instrument panel, console, door latches, strikers,

seats and hood latches. Failure to follow these

procedures may result in personal injury. Refer to

the appropriate vehicle shop manual to determine

location of the front air bag sensors. To deplete

the backup power supply energy, disconnect the

battery ground cable and wait at least one minute.

Be sure to disconnect auxiliary batteries and

power supplies (if equipped). Failure to follow

these instructions may result in personal injury.

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414-01-4

Battery, Mounting and Cables

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DIAGNOSIS AND TESTING

3. If the inspection reveals obvious concern(s) that

Battery

can be readily identified, service as required.

Inspection and Verification

4. If an obvious cause for a concern is found, correct

the cause before proceeding to the next step.

1. Verify the customer concern by operating the

5. Measure the open circuit battery voltage. If the

system.

battery voltage is less than 12.0 volts, test and

2. Visually inspect for obvious signs of mechanical

recharge the battery before continuing with

or electrical damage.

diagnosis

Visual Inspection Chart

6. If the fault is not visually evident, proceed to the

Mechanical

Electrical

pinpoint test below.

Battery

Battery cables

Battery mounting

Battery posts

Pinpoint Tests

PINPOINT TEST A : BATTERY CONDITION

Test Step

Result / Action to Take

A1

TEST BATTERY CONDITION

Yes

NOTE:

Failure to fully charge the battery before retesting may cause

Does the meter read, Good Battery? Return the
battery to service. Refer to Section 414-00.

false readings.

Does the meter read, Good Recharge? Charge

Verify the battery condition using the Battery Analyzer.

the battery and return to service. Refer to
Section 414-00.

Is the battery OK?

Does the meter read, Good charge & Retest
Fully Charge the battery and retest. Refer to
Section 414-00.

No

Does the meter read. Replace Battery?
INSTALL a new battery.
Does the meter read. Bad cell replace?
INSTALL a new battery.

important that it be given a thorough visual

Component Tests

examination to determine if it has been damaged. The

Battery Tests

presence of moisture on the outside of the case

and/or low electrolyte level in one or more of the cells

Tests are made on a battery to determine the state of

are indications of possible battery damage.

charge and also the condition. The aim of these tests

is to check if the battery is good, needs recharging, or

Battery Capacity Test

must be replaced. If a battery has failed, is low in

A battery can be tested by determining its ability to

charge, or requires water frequently, good service

deliver current. This may be determined by

demands that the reason for this condition be found. It

conducting a Battery Capacity Test. A high rate

may be necessary to follow trouble shooting

discharge tester (Battery-Starter) in conjunction with a

procedures to locate the cause of the trouble.

voltmeter is used for this test.

Hydrogen and oxygen gases are produced during

normal battery operation. This gas mixture can

1. Turn the control knob on the Battery-Starter

explode if flames or sparks are brought near the vent

Tester to the OFF position.

openings of the battery. The sulphuric acid in the

2. Turn the voltmeter selector switch to the 16 or 20

battery electrolyte can cause a serious burn if spilled

volt position.

on the skin or spattered in the eyes. It should be

3. Connect both positive test leads to the positive

flushed away with large quantities of clear water.

battery post. The voltmeter clips must contact the

Visual Check

battery posts and not the high rate discharge

tester clips. Unless this is done the actual battery

Some batteries incorporate a single one-piece cover

terminal voltage will not be indicated.

which completely seals the top of the battery and the

4. Turn the load control knob in a clockwise direction

individual cell connectors. This cover must not be

until the ammeter reads approx. three times the

pierced with test probes to perform individual cell

ampere hour rating of the battery. (A 61 ampere

tests. Before attempting to test a battery, it is

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Battery, Mounting and Cables

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DIAGNOSIS AND TESTING (Continued)

hour battery should be tested at 180 ampere

load.)

5. With the ammeter reading the required load for 15

seconds, note the voltmeter reading. Avoid

leaving the high discharge load on the battery for

periods longer than 15 seconds.

6. If the voltmeter reading is 9.6 volts or more, the

battery has good output capacity and will readily

accept a charge, if required. Check the specific

gravity. If the specific gravity reading is 1.230 or

below, add water if necessary and charge the

battery until it is fully charged. The battery is fully

charged when the cells are all gassing freely and

the specific gravity ceases to rise for three

successive readings taken at hourly intervals.

Additional battery testing will not be necessary

after the battery has been properly charged.

7. If the voltage reading obtained during the capacity

test is below 9.6 volts, check the specific gravity

of each cell.

8. If the difference between any two cells is more

than 50 points (0.050), the battery is not

satisfactory for service and should be replaced.

9. If the difference between cells is less than 50

points (0.050), the battery should be charged

according to the charging schedule. In some

cases the electrolyte level may be too low to

obtain a specific gravity reading. In such cases

water should be added until the electrolyte level

just covers the ring in the filler well, then charge

the battery at 35 amperes for the maximum

charging time indicated in specifications, for

capacity of the battery being tested.

10. After the battery has been charged, repeat the

capacity test. If the capacity test battery voltage is

still less than 9.6 volts, replace the battery. If the

voltage is 9.6 or more the battery is satisfactory

for service.

11. If the battery is found to be discharged only,

check for a loose drive belt, loose electrical

connections, charging system performance, and

make a battery drain test.

Battery Drain Test

This test will determine if there is any external load

that would cause unwanted battery discharge.

Disconnect the battery ground cable and connect the

positive lead of a voltmeter to the cable. Connect the

negative leads of the voltmeter to the battery negative

post. With all circuits off, the meter should read

<50mA. Any battery external load will cause the
voltmeter to read full battery voltage.

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414-01-6

Battery, Mounting and Cables

414-01-6

REMOVAL AND INSTALLATION

Battery and Cables

Removal
1. Disconnect the battery cables.
2. Remove

the

battery.

Item

Description

1

Battery Assembly

2

Bolt M8x190

3

Battery Hold-Down Clamp

3. Remove the hold down bolts.
4. Remove the hold-down.
5. Remove

the

battery.

Installation
1. Reverse

removal

procedure.

Battery Shroud

Removal
1. Remove shroud as shown in figure.

Item

Description

1

Clip

2

Battery Shield

3

Venting Tube

Installation
1. Reverse

removal

procedure.

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