Custom Battery Cables Home
Battery Cables for Cars, Trucks and Jeeps:
F150 & Bronco
1987-99 F250 & F350
1999-2003 F250 & F350
Jeep Cherokee and Grand Cherokee
Willys and Military Jeeps
1994 - 1998 Dodge Ram 2500/3500 5.9L Cummins
1998 - 2002 Dodge Ram 2500/3500 5.9L Cummins
2003 - 2007 Dodge Ram 2500/3500 5.9L Cummins
2007 - 2009 Dodge Ram 2500/3500 6.7L
Project Snow Leopard FJ dual battery set
Battery Cables for Other Applications:
2 gauge Golf Cart Cables
2/0 Cables for Solar Battery Banks
Braided Ground Cables
Booster (Jumper) Cables
Made-To-Order Custom Battery Cables:
Accessories, parts and tools:
NOCO Genius Wicked Smart Chargers
Battery and Cable Accessories
Battery Cable Repair Kits
Buy Wire, Terminals, Lugs, Heat Shrink and Tools
Clearance and discount cables.
Technical Info and Other Useful Stuff:
Do You Need New Cables?
Battery Cable Tips and Tricks
Different types of Cable Ends
Different Wire Types
What size cable do you need?
Wire size, thickness, amperage
How we assemble cables
Beware of PayPal Scams
I'm always getting asked ďDo I need new
Iím always puzzled by the question since I
canít really lift the hood and inspect the old ones by email.
However there are a few things to look
for that are dead giveaways that itís time for new cablesÖ
This is most often caused by the cables being attacked by the sulfuric
acid in the battery.
Batteries can leak acidic fumes where
the battery posts come thru the plastic housing.
It gets worse when some idiot at the
local discount store beats the battery terminal on with a hammer.
(I've seen them do it. I've even seen them do it even
after I told them it would damage the battery.) This causes cracks and damage to
the fragile post-to-case seal.
Using the battery washers helps create
another barrier to the fumes.
Sometimes the corrosion is hidden under
Look for wires that are swelled up near the
ends or near cracks in the insulation.
The green fuzz that forms on the wires
is copper sulfate and is poisonous to both plants and animals.
glasses, gloves and other protective gear and always wash your hands.
Cracks in the insulation are points where acid can enter and attack
the wire. If they haven't started corroding yet, you can pretty
much bet that they will eventually.
Cables can burn from contact with headers or other exhaust components.
If the cables are undersized they can quickly get very hot especially
during extended or excessive cranking.
Sometimes they get so hot that the
insulation actually melts or burns.
for insulation that is misshapen or deformed from melting and then
cooling into its new shape.
If you look closely you will see that this factory lead terminal
is cracked. This could be due to many reasons but often it's from
over tightening especially if connecting additional wires under
the battery bolt. If you need to connect
extra wires, buy cables with
terminals with extra wire capability or get extra wire nuts/bolts.
I tighten them until I can no
longer twist the terminal on the post then I go an extra 1/4 or
1/2 turn. To get a good
electrical connection, you need a good mechanical connection.
It needs to be clean and tight but over tightening doesnít
make it work any better.
Electrical problems are much
harder to find than physical issues. You canít just look at the wire and
tell if thereís an electrical problem. If the wire is getting hot during
cranking, it probably has a hidden defect or is undersized.
The rule of
thumb is there should be less than 0.5V voltage drop, round-trip from
the positive battery post to negative battery post during cranking. This
can be measured with a voltmeter. Put one lead on the positive battery
post and the other on the starter stud. Have an assistant crank the
engine and record the voltage while the engine is cranking. Do the same
thing for the negative side. Put one lead on the starter case and the
other on the negative post of the battery and measure the voltage with
the engine cranking. Add the two numbers together and the sum should be
less than 0.5 V.