Engine/Transmission (1994 - 1998) how to repair battery cable terminals?

[CTaylor]

Im putting 2 new batterys and hold downs in my 97 and also need to replace 2 of the end terminals due to the bolts inside becoming corroded and tearing the ends out of the soft lead terminals when I tried to remove them. Is this going to be a pita?



Do I need to just cut the terminal ends off close on the cable and strip a little insulation and attach new ends? Sorry for the dumb question, I just dont want to screw this up and end up with cables that are to short and wont reach the posts on the batterys

 

[hsmith]

I would use good terminals, the solder type. In the future, to prevent a reoccuring terminal problem, you may consider acid free batteries. I am very pleased with my dry cells.

 

[HHhuntitall]

Personally, if it was my truck, I'd replace the whole cables. I keep my trucks, so it's a small investment on a larger tool..... there are quite a few aftermarket cables of adequate guage weight to take the amperage load and hold up. Try NAPA or Orielly's to see what they have. Orielly's lists this for the '97. Super Start SK8456CR - Battery Cable 1997 Dodge Ram 2500 | O'Reilly Auto Parts It's a little light for my tastes, but it will work fine. I've got extras from trucks I've dismantled, or I'll go with OEM, myself.



NAPA may have something heavier, which is why I suggested them... .

 

[WDixon27]

i did this
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hummer battery terminals from ebay fairly cheap and solder on lugs, easy to clean and gives a few more places to attach accessory lugs

 

[CCiatteo]

^^^^^I did this same mod to my truck when I was chasing starting problems and was able use the factory cables (still in good shape). I just took a hacksaw to the factory end, cut it off and soldered on a new lug. The military style connector shown above is the ticket for easy maintenance and long terminal life. It completely removes the tendency to overtighten the OEM style terminal ends, which ultimately leads to failure. I bought mine from Mc-Master Carr for like $5 a piece.

Chris

 

[HHhuntitall]

I like that, above. I use terminal batteries, sometimes, and use those ends on all my farm tractors and truck tractors. They work really well, even better, IMO, than the posts with the side contacts..... but if that's what you have, make it work!!

 

[Grizzly]

Personally, if it was my truck, I'd replace the whole cables. I keep my trucks, so it's a small investment on a larger tool..... there are quite a few aftermarket cables of adequate guage weight to take the amperage load and hold up. Try NAPA or Orielly's to see what they have. Orielly's lists this for the '97. Super Start SK8456CR - Battery Cable 1997 Dodge Ram 2500 | O'Reilly Auto Parts It's a little light for my tastes, but it will work fine. I've got extras from trucks I've dismantled, or I'll go with OEM, myself.



NAPA may have something heavier, which is why I suggested them... .

Totally agree. Just replace the cables. Probably cheaper in the long run.

 

[GCroyle]

I replaced the ends on my '97 several years ago. Belden has HD brass crimp ends available by gage and +/- end. My neighbor has all the crimping tools req'd cause he is a lineman, overwith before I could say what was that you just did. I previously posted my repair.

 

[stg2500]

I also installed the military style battery terminals. Very easy to do. I have been very satisfied since I did it a couple of years ago.

 

[JKosten]

When I was due to change out my batteries I decided to go bigger and better: two CAT group 31 stud top batteries. They have 1000CCA's each and are vibration resistant. I also replaced all the cables with 1/O cable. The difference is night and day on cranking speed and not having the lights dim anymore.



Now I know that the max current the starter can draw on a cold day is 700-800a so it has approximately 3 times the available power that the stater needs.



If you chose to go oversize on batteries then the cables must be changed to match the current increase. Along with that the factory cables may appear to be okay, but on my 96 CA truck the cables all had corrosion under the insulation.



The other part about oversize batteries is that the tray has to cut to allow the longer battery to fit. I used a corner bracket through an existing hole to limit forward travel of the battery.



I also switched the polarity of how the batteries sat in the tray to reduce hood arcing possibilities.



(Also I ended up having to do the whole job in the rain at night... )



Optima and CAT 31

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Battery box cut

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Factory cable vs 1/O custom fit

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Drivers side installed

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Passengers side installed

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[harrisonm3]

How many feet of 1/0 did you use?

I'm going to order all of the parts with military terminals and install it before the winter.

 

[JKosten]

How many feet of 1/0 did you use?

Ummm I would have to measure it but I know I had a 25' piece and there was some left over.



I would recommend doing a quick measure before you order parts.