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Battery Cable Assembly Issue

PNW3500

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First post here.

I bought a brand new 2023 3500 6.7 HO SRW Crew Cab Laramie Night Edition on 8/08/2023. Already put about 3500km's on it and have been extremely happy with it.

8/27/2023
Was out camping on a FSR in BC with <3500km. The morning we plan to leave I remote start the truck and it turns on, my wife jumps in the passenger side and I walk around to the drivers side to get in. The minute I open my door the whole truck shuts off and the truck goes black. No power at all, initially I thought it was a security feature potentially with my wife jumping in first on a remote start but that was ruled out. I popped the hood and no fuses were blown, tried jump starting and nothing.

Ended up driving an hour back into town to get into service and called roadside, prompt service gets me a tow truck he picks me up and we head out to the truck (Im told Ext. Warranty doesn't include offroad towing so that $600 out of my pocket, I am going to try to expense it anyways). We arrive at the vehicle and he grabs a bypass cable to troubleshoot the issue, he ends up bypassing the positive cable from the battery to the fuse panel and we get power again. After tugging on the cable, power holds and we're under the impression that the cable has a bad wire. I drive it out, he follows, on the way back the cable shorts out 3 more times, cutting power to everything.

It lands at the local dealer they call me the next day to confirm the cable had an issues. Their write up was the following.

"Positive battery cables were disconnected from the Main battery cable assembly and continuity test performed. Found intermittent connection on one of the power studs, continuity would read 0.08 Ohms up to 220 Ohms depending on how you moved the battery positive cable assembly. Recommend to replace battery positive cable assembly."

This part is 68528645AA - Battery Cable Harness and it's a special order which takes 8-10 business days to arrive. They replaced/ tested it and called me for pick up on 09/07/2023.

This morning 9/11/2023 my truck would not autostart, walk up to it and there is no power. Pop the hood and pull on the same wire and power comes back. Currently in the process of having FCA escalate this to a specialist again.

I think there is a bigger issue with the terminals or fuse panel causing the cable to loose continuity. This has been a very frustrating start to owning this new vehicle.

To be continued.....
 

jerryw1000

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Could it be an internal positive battery terminal problem?
 

PNW3500

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They confirmed the positive wire assembly was the issue again...

They are claiming that it was a manufacturing defect, the crimp was done incorrectly causing a wire to pinch. They are ordering another assembly and checking it over before installing..
 

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