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Electrical

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2/17/2025

Anthony
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Title : Battery Disconnect Switch Replacement - Best Practices
Applies To : All Models with Battery Disconnect Switch

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
02/28/2025 - Initial Article Release

DESCRIPTION
This document will guide the user through additional steps that can be taken when replacing a failed battery disconnect switch,
that can extend the service life of the replacement battery switch.
NOTE: The steps outlined below are only "best practice" recommendations and are not required for every battery disconnect
switch replacement.
NOTE: The steps below should not be performed proactively but only when a battery disconnect switch is replaced.

SYMPTOM(s)
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light

Description

N/A
Customer Observations or Concerns:
Battery disconnect switch failure due to excess corrosion.

SPECIAL TOOL(s) / SOFTWARE
Tool Description

Tool Number

Comments

Instructions

N/A
Tools Resource Center

SERVICE PARTS INFORMATION
Kit Description

Part Number

Quantity
Notes
Required

Switch, Battery Disconnect

3554630C91

1

Dielectric Grease

Source Locally

1

Non-metallic Isolating Washers

Source Locally

2

DIAGNOSTIC STEP(s)
No diagnostic steps are necessary.

REPAIR STEP(s)

Rubber or nylon
0.75in ID, 1.125in
OD Max

REMOVAL PROCEDURE:
1. Park the vehicle on a hard, flat surface, turn the engine off, set the parking brake, and install wheel chocks to prevent the
vehicle from moving in either direction.
2. Remove the ground cable from the negative terminal of the battery.
3. Remove the control knob, locking nuts, lock washer, and faceplate from the disconnect switch.
4. Lower the disconnect switch through the floor and remove the battery cables from the switch assembly.
5. Removal complete.

INSTALLATION PROCEDURE:
1. Connect the battery cables to the replacement battery disconnect switch.
2. Apply a liberal amount of dielectric grease to the locations called out in Figure 1.
3. Install the first rubber washer over the threaded section of the disconnect switch.
4. Position the disconnect switch through the hole in the cab floor.
5. Install the second rubber washer over the threaded section of the disconnect switch.
6. Install the lock washer and the first retaining nut over the rubber washer.
7. Install the label faceplate, followed by the last retaining nut.
1. See Figure 2 below for the order of installation.
8. Install control knob.
9. Reconnect the battery and test for proper operation of the battery disconnect switch.
10. Installation complete.

Figure 1: Locations of dielectric grease application

Figure 2: Battery Disconnect Switch Order of Installation

WARRANTY INFORMATION
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

OTHER RESOURCES
Master Service Information Site

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