[therabbittree]

While I had the heater hose area apart I noticed a large bulge in the alternator cable . Well after dissecting it I found a nice suprise. The cable had been attached by splitting the cable into two smaller portions and using WIRENUTS
I figured I was in for more of these discoveries. Ha I found that the stock 5.4 gas fords have the starter relay on the pass side. The cummins starter is on the drivers side. The truck was wired with the cables leaving the drivers side, travelling to the pass side and then back to the drivers side. The Cruise control was also mounted on the passenger side and not hooked up. The Batteries were not secured very well, and they were not very strong, and I wanted to add a grid heater.
So I opened the wiring up and pulled the relay wires out, moved the cruise control and starter relay to drivers side, fabricated a new battery tray, sodered new alternator cable, and upgraded to new 2/0 battery cables.



I discovered the EGT / boost wires along with the stereo power were run into the cab with out any grommets on the holes..argh. The holes also passed though some brackets on the inside that hold the ecu.
more to follow....