hayman75

I finally completed my WT mod. The first part of it had solved my TC lookup issues but I was having other issues so I completed the mod. I used a 150 amp fuse in this plastic housing I got off amazon. Reused the old charge lead cable, cut into sections. The fuse is easy to access and I have two extras in the cab. Grounded the ground wires from the front wire loom to the back of the gear cases. Everything has been working great. I still have my lift pump on a manual switch but for now its all running good.

Two similar questions figured I'd combine them. I've had this truck for almost a year now and in the process of fixing some minor and major things. First is the passenger side headlight has some play in it, enough that it can, at times, be noticeable when driving. The assembly itself has a threaded alignment pin on the back, see the attached picture for reference. When I wiggle it compared to the drivers side headlight, this appears to be where the play is. After removing the market light you can get a couple fingers back there and the driver side one appears to have some sort of retainer, a clip or something that hold this pin tight. Does this sound right? Since there is barely any access back there it can't be nut right? Its hard to tell just by feeling but it feels like something is on that pin. The headlight replacement videos I've watched do not mention anything special about this, Any help is appreciated. Second question - With the front bumper off, on the passenger side just below the headlight there is a wiring plug with the other end broken off inside it, See second picture. I haven't inspected it real close yet but tomorrow I should have some time to pull the broken end out. It appears to go into the same loom as the head. Any ideas?

The crossover, starter, charge lead, and both ground to block cables are 2/0awg, which I think is the same as stock expect for the charge lead, much beefier. The PDC cover won't close properly, I'll get it moved once I decide on where to place the fuse. The rest of the grounds and battery to PDC are 2awg which is larger then stock. The driver side positive is cluttered, my battery can have top and side posts. So I may install the side post and get another military terminal and move two of the cables down.

I haven't settled on a good position for all the power cables. As I said the cable to the starter was a bit long so I had to bring it up and around. Ground lines are all good, much larger cables.

Just wanted to wrap this up. Replacing the cables wasn't near has hard a I thought. Hardest part was monkeying around underneath with the cable that goes to the starter and the small sensor wire. The cables from the kit I got were a little long which for the crossover cable was nice but a little hard for the starter cable and driver side grounds. I didn't change the charge lead, still thinking on where to place the circuit breaker. I did put the new lead in its own loom so its easy to replace when the time comes. The larger cables and military terminals have it running great. Nice upgrade glad I did it.

Question on this, is there anything that needs to be done about the bolts? I bought the Mahle kit which came with rubber washer with a steel washer. I didn't use these as they are thick and it seemed like you should use longer bolts if you use the,. I just put back on the same bolts with the same washer. Mine was was leaking slightly from the bolts so is there a new washer kit or is this not of concern? Good write up.

I have all this from the kit. I think I'm going to for it and do them all. Has there been a consensus on the need for a fusible link or fuse when rerouting the charge lead?

I did the half way version by pulling the ground wire from wire loom that goes by the alternator and grounding it to the driver side battery. That solved the TC lock/unlock issue at 45mph I was having (which was worse during rain storms for some reason). I'll look into the full version.

I am in the throes of replacing the crank seal, tappet cover gasket, radiator, and intercooler. With the good access, and since I plan to keep this truck, I figured I'd replace the battery cables. No real issue just tired of the corrosion and poor stock terminals. I ordered a nice pair from K Suspension but the install instructions leave a lot to be desired. Information is limited from other sources, anyone every tackled this job? One part that seems daunting is the many sensors that share the wire loom with the power cable going to the starter. Getting that apart and keeping it all straight must be a challenge. Any advice is appreciated. 2001 2500 Quad Cab - Bone stock