Battery Disconnect Light comes on...transmission goes into limp mode- only 5 gears

[Mullaney]

Update:

I want to thank everyone for your comments up this point.
Yesterday I was removing some of the terminals from the LBCD, starting with the top one. I put it all back together and, as you know, nothings would start.

Today, I was able to pull the LBCD, which was a total pain to explore it more. While doing so (with the power on), I was removing the top terminal and I could hear the all the buzzers in the interior turn on!

View attachment 871082

From the prior day, I inadvertently sheared the stud on the 24V Batt terminal. This was an oversight on my part - I think this is a special stud. Notice the threads taper to a smaller diameter?

View attachment 871081

The other issue is that the nut that was epoxied into LBCD was loose and can be removed.
View attachment 871083

Here is a picture of the little bit of the stud still inside the LBCD.
View attachment 871084

So, I need some recommendations.
1. Do I attempt a repair or do I need to replace?
2. If repair, how to secure the nut into the LBCD? Epoxy, some other adhesive?
3. Do I attempt to remove the bit of stud?
4. If yes, any ideas on where I can buy a replacement?
5. If no, do you suggest a conductive paste or another solution?
6. Did I forget to ask anything?

Thanks in advance guys. You have been very helpful!

By the way, I checked all the battery voltages today. All stable at 12.4V- 12.8V

.
Well, I guess the happy part is that you found your problem. My opinion is that there isn't any way to reliably repair it. You already know what a PITA is was to take it out. Putting it back won't be any easier. The third time when you are on the side of the road when the epoxy shakes itself loose (and it is raining and cold) will be a Royal PITA.

It is possible that you can find one here on the Parts Wanted (Classifieds) Section. @wheelspinner or @TacMac2012 occasionally have M107x or M108x trucks that are scrapped for parts. They could be a good source for a replacement...

 

[Ronmar]

Replace it or bypass it…

 

[Suprman]

I have one. While you are at it open the box next to the battery box with the disconnect relay see if you have the old or new style.

 

[coachgeo]

I have one. While you are at it open the box next to the battery box with the disconnect relay see if you have the old or new style.

If not @Erik Erickson am sure others will likely need to know the difference between the two when they search this topic

 

[Suprman]

He can describe it or post a pic

 

[Ronmar]

Oh, and drop to two batteries

 

[GeneralDisorder]

Yeah that's wrecked. Throw that in the f*ckit bucket.

I got a used one on ebay for $100 that was in good shape - studs all cleaned up like new. Make sure there's no black stain of capacitor electrolyte leaking out of the back where it's potted.

In the meantime just bolt the battery and load cables together with star washers, wrap them in splicing, cambric, and electrical tape and run it that way.

The old style battery disconnects have problems with solder joints and terminals. The new style is like $500 but fully potted/enclosed etc.