Busted Battery Connector

[Tulsa618]

I find I’d overtightened one of the battery terminals – to the point that the connector itself split! Duh! Anyway, Mopar wants about $85 for a replacement cable. Seems it can fixed cheaper, but I wanted to make sure I’ve good contact for all the wires that flow from the terminal. (It’s the ground terminal on the passenger side battery. )



My symptom: danged transmission hunting that seems to be worsening at an accelerating pace. Last time that was a problem (that neither Dodge nor my favorite transmission shop could figure out or fix), the problem disappeared when I replaced my batteries. Apparently, the transmission was just needing full juice… Of course I’ll have my batteries checked out again (they’re about 18 month old Interstates), but I want to make things right with that connection.



What would be the best course of action? Should I bite the bullet and shell the bucks to Mopar or are there other options I could take? Thanks!

 

[Thomas]

This item is available from Wrangler NW Power Products. I imagine similar products are available locally. While designed to be crimped to the 2/0 battery cable with a 'spendy' tool (also available at Wrangler NW Power Products) the lug can be soldered to the cable.



Rather then spend the $85 at D/C, I'd find a fast way of replacing the damaged lug.



I noticed that the OEM lugs on my model year 2000 Ram didn't tighten well after several remove/replace cycles. My solution was to use the 'military terminal' and soldered lugs (all from Wrangler NW Power Products) shown in the attached photo of my passenger-side battery.

 

[Thomas]

The military terminals make it easy to add wires and don't degrade the connector at the end of your cables, even with hundreds of remove/install cycles.

 

[Tulsa618]

Thanks, Thomas! I'll look right into the WRangler NWP.

 

[Thomas]

If you need info on how I removed the original lugs and soldered the replacement lugs without shortening the cables shoot me a PM.

 

[SSchulte]

what about drivers side batt cable

 

[Thomas]

what about drivers side batt cable

The attached closeup photograph is the driver's-side +12 v. cable. What else do you need?

 

[MKinner]

has anyone ever checked out this site? www.quickcable.com

they have a ton of stuff for servicing batteries

making jumper cables, they even sell sleaves that you

can put over worn post so you can tighten up your old

terminals.

 

[Willys]

Thomas, what is the method you use for removing the terminals? I'm probably going to just replace the cable with quality welding cable, but then again I might not.



Are the new cable ends crimped, soldered, or both?



And sorry for bringing a thread back from the dead

 

[Thomas]

Look at the 9th post in this thread.

 

[rbattelle]

www.waytekwire.com carries a large selection of battery terminals.



www.weldingsupply.com carries some very inexpensive crimping tools ($20 or less).



-Ryan

 

[rweis]

I made a new battery to battery cable from marine battery cable. The marine grade wire is tinned in the manufacturing process to prevent corrosion later.



Bob Weis

 

[Willys]

Thanks for the help.



Waytek is a good source for parts, but I really like Del City too(a little more selection). Mouser Electronics has a good selection of switches and other misc. 12V parts if you want to wade through a phonebook size catalog that would make any EE happy.



I was wondering also if any of you have used the Priority start device?

www.prioritystart.com I'm thinking about getting the pro version...



MKinner, I thought quickcable is wholesale only. I wish the site showed the prices...

 

[Melkers]

anybody try this guy? I'm looking at his cables and they seem to be just what I'm looking for.



http://www.custombatterycables.com/application/dodge_ram.htm

 

[Willys]

They look pretty well made.



I ran across this link a few minutes ago(for military clamps)



http://www.pwrtap.com/products/clamps/index.html

 

[Willys]

These insulators look like they would fit on the military lugs:



http://www.vteworld.com/cgi-bin/P_D...tID=90&CF_PageNo=7&CF_PageType=ProductDetails



http://www.vteworld.com/cgi-bin/P_D...tID=87&CF_PageNo=7&CF_PageType=ProductDetails



and for circuit breakers:



http://www.vteworld.com/cgi-bin/P_D...tID=97&CF_PageNo=9&CF_PageType=ProductDetails



oops, minimum order of 1000... . Anyone want a TDR group purchase?



Ok, found a distributor for the above parts. They also sell the marine style terminals Thomas used.



http://www.stellmar.com/

 

[Willys]

In case anyone wanted another source for the military terminals, I ran across this:



http://www.premierpowerwelder.com/terminals/terminals.html