Cummins Diesel Forum banner

Anyone rebuild battery cables/connections?

5885 Views 37 Replies 13 Participants Last post by  NCC74656
We're currently experiencing intermiittent no turn/over-clicks, and we know that our terminal connections are lousy. Had to carve lead out so the two sides of the clamp couldn't tighten together better. I saw someone in a youtube video do a rebuild of the positive battery to battery cable using military type connectors and Fusion solder lugs. Has anyone done this all the way around? I'm thinking we could re-use some of the longer cables/wires since there'd be enough length to cut and then do the lugs. I've read elsewhere that you shouldn't use the solder type because the wires can heat up and melt the solder - true? The youtube video was done on a 2001 CTD and the end result seemed so nice...

I'm wondering what size lugs to use for the smaller wires - combine them into one lug?

If you've done this, solder or no, what size lugs did you use for the various connections?
1 - 20 of 38 Posts
I was planning to do it last summer, but $300 for the correct parts and new cable was too expensive for me. I ended up just putting in sheet metal screws in the posts to fix it, $0.50.
  • Like
Reactions: 1
I was planning to do it last summer, but $300 for the correct parts and new cable was too expensive for me. I ended up just putting in sheet metal screws in the posts to fix it, $0.50.
:eek: LMAO I DID THE SAME THING!!!
IT LOOKS LIKE CRAP BUT HAS BEEN THERE OVER A YEAR NOW.
SAD WITH ALL IVE DONE UNDER THE HOOD AND THAT IS USUALLY WHAT PEOPLE COMMENT ON FIRST. "DAM THAT IS WTF IS THAT SCREW"
:D

Sent from AutoGuide.com Free App
  • Like
Reactions: 1
I took my cables that had bad ends to napa and they put new ends on so everything tightens correctly. Only costed me 18$ for parts and the time it took them to put the ends on.
I just took care of my trucks and never had to replace terminal on either my 2002 or my 1996 Dodge as of yet still have the factory terminal end and never been corroded yet.

Much cheaper than having to replace them...
Yeah i would say so but that's what I get for buying a truck with 180k on it
Ok, so I'm looking for advice on how best to do this - they're already crapped out so taking care of them is moot:banging:
Ok, so I'm looking for advice on how best to do this - they're already crapped out so taking care of them is moot:banging:
Me personally I would get a new lengths of welder cable and solder on new terminals on both ends (battery terminal and ring terminal). Then take care of them properly.

I would ditch the old cable because if the terminal is bad and the cable is most likely going south internally from corrosion.
In a pinch I've used steel wool around the post and then clamped over top of it. Use enough and it makes a good filler. I wouldn't run it like that for long periods of time because steel wool is very prone to rusting out, but it could get you by for a couple days if needed.
Welder cable is easy to find online. I bought 25 feet for a winch one time(0awg I believe) it was like 35 shipped to my door.


Sent from AutoGuide.com App
i ran all new wire for mine. 0ga grounds and power for nearly everything and soldered on new ring terminals. i use a brass post and fittings to bolt the ring terminals directly to the battery studs. its a very easy fix.
  • Like
Reactions: 1
I replaced mine with OEM ones from moper-wholesale.com they're alittle pricey, but exactly what's already there.
i ran all new wire for mine. 0ga grounds and power for nearly everything and soldered on new ring terminals. i use a brass post and fittings to bolt the ring terminals directly to the battery studs. its a very easy fix.
Since you did this with new wire, can you tell me what gauges all the various smaller wires are? I already bought new battery to battery red battery wire from NAPA, expensive! Glad to know about using welding wire!
welding wire is fine for many things but i prefer to use high strand count OFC (oxygen free cable) cable for all my power wires. I pull a ton of power through my trucks batteries (4 group 31's) so my needs warrant going a bit over board.

the smaller neg wires are body grounds or maybe some accessory grounds from after market parts such as lights. anything that is connected to your posts by ring terminals you will need to track back to see what it goes to (if anything). when i bought my truck i removed a good 300ft of junk wire from tits and tats that were installed once upon a time and then removed and forgotten about.

the positive terminals on the passenger side should just be an interconnect to your driver side battery and on the driver side is a 8ga going to your fuse block and a 0ga going to your starter. these are thick stranded wire that is pretty imo. I am building a setup to run a 5th smaller battery with a diode so it will power the trucks base systems from the fuse distro block (factory) off a dedicated 12V power source adn the rest of my truck will be a 18V system.

here are some pics of my batteries from durring the install, they are wraped better now and the plate is encased in its plexi enclosure. imgur: the simple image sharer

thats a 420A alternator in there as well, if you are upgrading your alternator i recomend running a dedicated ground from the mount bolt to your battery and 0ga from the alt terminal to your battery or distro block.

this is the wire i recomend for light to medium power install (say anything under a 400A draw).

its very easy to work with and carries a good load.


edit: forgot to mention that this wire i linked is copper/alum. power (electrons) travel on the ousdide of wire in what is known as the skin effect. thus to save money cheaper wire is a copper wrapped aluminum rosin core. thismeans that its cheaper and still carries the same amount of electrons BUT it can not handle the same amperage as it will heat faster and fail. now i mentioned that > 400A is fine for the length of runs you will see in your truck on this upgraded wire but if you want to install some high end stereo equipment or high power draws (such as a winch) then id recommend some of this wire: http://www.amazon.com/0GA-Audio-Black-Flexible-Power/dp/B00CA4ZTMS/ref=sr_1_7?s=automotive&ie=UTF8&qid=1384115097&sr=1-7&keywords=0ga+ofc


See less See more
welding wire is fine for many things but i prefer to use high strand count OFC (oxygen free cable) cable for all my power wires. I pull a ton of power through my trucks batteries (4 group 31's) so my needs warrant going a bit over board.

the smaller neg wires are body grounds or maybe some accessory grounds from after market parts such as lights. anything that is connected to your posts by ring terminals you will need to track back to see what it goes to (if anything). when i bought my truck i removed a good 300ft of junk wire from tits and tats that were installed once upon a time and then removed and forgotten about.

the positive terminals on the passenger side should just be an interconnect to your driver side battery and on the driver side is a 8ga going to your fuse block and a 0ga going to your starter. these are thick stranded wire that is pretty imo. I am building a setup to run a 5th smaller battery with a diode so it will power the trucks base systems from the fuse distro block (factory) off a dedicated 12V power source adn the rest of my truck will be a 18V system.

here are some pics of my batteries from durring the install, they are wraped better now and the plate is encased in its plexi enclosure. imgur: the simple image sharer

thats a 420A alternator in there as well, if you are upgrading your alternator i recomend running a dedicated ground from the mount bolt to your battery and 0ga from the alt terminal to your battery or distro block.

this is the wire i recomend for light to medium power install (say anything under a 400A draw). KnuKonceptz KCA Kable 0 Gauge Power Wire Black : Amazon.com : Automotive

its very easy to work with and carries a good load.


edit: forgot to mention that this wire i linked is copper/alum. power (electrons) travel on the ousdide of wire in what is known as the skin effect. thus to save money cheaper wire is a copper wrapped aluminum rosin core. thismeans that its cheaper and still carries the same amount of electrons BUT it can not handle the same amperage as it will heat faster and fail. now i mentioned that > 400A is fine for the length of runs you will see in your truck on this upgraded wire but if you want to install some high end stereo equipment or high power draws (such as a winch) then id recommend some of this wire: Amazon.com: 0GA - Skar Audio Black 0GA 50ft Roll Flexible Power Cable: Automotive


Where/how much was that alternator? I have a 5k inverter (8k peak) and I need more power for it for me even to consider putting it in. I also will be putting 2k watt stereo soon. Got the amps now saving for subs haha. Got components/head unit.

Sorry for Hi-Jack!

Good thread! I need to fix my cables soon also, cheap clamp on ends................gotta love my father haha! Being a mechanic his stuff was always the quickest fix.

Thanks, Brad.
NCC74656, your response was very helpful - thank you! We're stock so I will go with welding wire. The interconnect positive cable was 2/0 - I thought the ground going to the engine block and the positive going to the starter were of the same gauge..I appreciate the help, especially inept with electrical stuff!
no problem.

i also run a 5KW power inverter (11K peak) and a 1200W amp, 500W amp, 550W amp, and 2 5500W amps in the truck for front speakers, tweeters, and subs. my alternator is a mechman and it works great. ive seen people put 40 batteries on a single alt with out issue, they also come with a voltage regulator so you can go from 13.8-28V as you choose.

if you go with subs id HIGHLY recomend Fi audio. i have built many systems with them and i can tell you that a single 12" Fi BL dominates 2 15" kicker L7's in volume and quality of audio/frequency responce.

Fi Car Audio, Custom Car Audio, Made in the USA | Join the Revolution!

ive used there SSD's, BL, SP4, and Q's. presently i run the SP4.
Dodge Battery Cables from CustomBatteryCables.com

there is also tons of info on this site about types of cable, what ga to use, and connection types.
Thank you for that link! So, you said you used 5 x 8/10 connectors for the smaller leads...Being a dunce I need clarification based on what I'm seeing in our truck.

On the passenger side ground connection, there's the smaller grounds, one to the body and the other that splits and has the plastic connectors inline. Those two wires are of different sizes. All I can say is that when I measured the diameters they were about 11/64" and 13/64" - so do those 8/10 lugs work for both of those?

Same on the driver's side: The positive wire going to the fuse box is 1/4" diameter so what size connector...?

Sorry to be so dense on all of this but I can't drive the truck to NAPA to get it figured out!
1 - 20 of 38 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top