8
Lit. No. 63617
September 13, 2002
UNDERHOOD INSTALLATION
arness Connector
Plug Cover
VEHICLE HARNESS AND MOTOR RELAY
(continued)
3. Find a location for the motor relay where it will be
protected from road splash and will be within 18" of
the vehicle primary battery.
NOTE: Motor relay terminals must be up or
horizontal.
Using the motor relay mounting plate as a
template, drill two 9/32" holes, and mount motor
relay to holes using 1/4" x 3/4" bolts, plain
washers, and lock nuts.
4. Route 22" red battery cable between a large motor
relay terminal and the POSITIVE battery terminal
taking care to avoid sharp edges, and hot or
moving parts.
At the motor relay large terminal,
Attach in the following order:
• (2000 model year only) Ring terminal from the
fuse holder assembly found in the harness kit
(See picture below.)
• Red wire ring terminal from the park/turn lamp
harness kit found in the mount box
• 22" red battery cable end
• Secure all terminals with a lock washer and
5/16"-24 jam nut
Both the fuse holder assembly and the park/turn
lamp harness will be routed to the headlamp relays.
Part No. Qty. Description
91055 2 M6-1.00X25 HXW CS G8.8
91056 2 M6-1.00 HX NUT
91119 6 3/16 PLAIN WASHER
At the positive battery terminal clamp,
replace the original equipment battery clamp cap
screw with the blue chromate finished cap screw,
one 3/16" plain washer and 6mm nut listed below.
Use two 3/16" plain washers and a second 6mm
nut as shown in diagram to attach the 22" red
battery cable end to the battery clamp.
5. Stretch rectangular openings of plug cover straps
(found in harness kit) over harness connector ends
of long battery cable assembly (found in hydraulics
box) and vehicle harness (found in harness kit).
Place plug covers over molds on harnesses.
6. Find a location in the vehicle grill or bumper
openings on the battery side for the battery cable
harness connector. The best location is at least
10-1/2" from the center of the grill and at a
convenient height for connecting the plow plugs.
Allow harness connector of each harness to hang
out in front of grill. Allow enough cable so it is easy
to mate and remove connector. Secure with long
cable ties (found in mount box).
7. Route battery cable through the grill at the selected
location and through or around the radiator
bulkhead to motor relay taking care to avoiding
sharp edges, and hot or moving parts.
8. Attach cable with red stripe to the unused large
terminal on the motor relay, and secure it with a
lock washer and 5/16"-24 jam nut.
(continued on next page)
Fuse Holder Assembly
(2000 Model Year Only)
To Motor
Relay
Battery
Terminal
To
Relays
Fuse
Holders
22" Red
Battery Cable
Furnished
M6 Nut
3/16
Plain
Washer
Battery
Terminal
Battery Clamp
Existing
M6 Nut
Vehicle
Positive
Battery
Cables
Furnished
M6-1.00 x 25 mm
Cap Screw
3/16 Plain Washer
