1999 Ford E-150 Econoline "Chateau" V8 Triton 4.6L VIN: 1FMRE11W4XHA22592

When I connect the battery a cable/wire starts smoking. From the attachment can anyone tell me what the cable is.and how to fix the issue.

Thank you

 

So XC2Z14300BA is the part number and it's discontinued, even a used one is probably not available. Best thing you can do is to remove it (check pdf below) and do the repair or DIY build one on the bench.
BTW if you plan to replace the battery terminals to the battery posts you might want to look for a long reach with 90 degree bent. On your van there was a design flaw by Ford for not using a 90 degree bent out from the factory, a sharp battery cable bent (after the top post) as a result.

 

It might be a good idea to clue us in as to what was done and why the battery was disconnected..

If the problem was not there before the work it,,,,,, has to be something related to what was done.

 

Look at the diagram above, the red battery cable (not fused) connects to the starter solenoid at the starter motor, and another one (also not fused) connects to the fender-mounted starter relay, last one to the aux battery (if equipped). Either one of the three is shorted to ground, that's why no fuse blown. And it's unsafe (could catch a fire) to fix it with just electrical tape.

 

Thanks very much Hanky. The battery was disconnected to store the van over the winter. Its cold up here in Canada:-) THe snow has only just melted.

 

Sorry I meant thanks Heiko

 

The battery was disconneted to store over the winter. No work done.

 

Thanks again for the awesome information. This is a great help. Have a great weekend.

 

I've added another photo to the attahed description. It shows where the cable terminates. Does this jive with the diagrams you have sent to me?

 

Hi Heiko,
He

re's a photo of the other end of the cable. Does this fit with the drawings you have sent. We looking at the image the cable terminates at the right hand nut. There is a plastic cover. The right hand side is annotated with a + and the left hand side says ALT.