Del City Blog

How To Install Battery Cable Repair Splices

Posted by Lauren on Nov 11, 2016 10:45:28 AM

Quickly and conveniently repair cable harnesses with battery cable repair splices. Instead of replacing the entire harness, simply replace the damaged or corroded battery terminals. Plus, even with the repair splice, you'll still have an OEM style fit!

Remember, use a high temperature sleeving to protect against heat and abrasion when necessary.

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IMPORTANT: Batteries produce explosive gases. It is critical to follow all safety instructions, and to always wear safety glasses when working near batteries.

 

Parts & Tools List

Battery Cable Repair Splices

Terminal Wrench

Cable Cutter

Wire Stripper

Wire Crimper

Hex Wrench

 

Step 1

Turn off all electrical loads on vehicle. Set parking brake. Place automatic transmissions in “PARK”(manual transmissions in “NEUTRAL”).

NOTE: Before proceeding, consult your owner’s manual or service specialist to determine if special procedures are required before disconnecting your battery. 

 

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Step 2

Locate and disconnect ground cable from the battery. The ground cable is the cable wired to the engine block, vehicle frame or other metallic ground.

 

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Step 3

Disconnect other cable from the battery. This cable is the one wired to the starter or solenoid.

 

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Step 4

Remove old terminal that is to be replaced by cutting off the wires attached to it. Cut the wires as close as possible to the old terminal.

 

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Step 5

Strip insulation with your cable stripper from remaining auxiliary lead 1/4" and remaining main cable(s) 3/4".

 

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Step 6

Insert the stripped end of auxiliary lead into appropriate butt splice and crimp using a crimp tool. Repeat if there are additional auxiliary leads.

 

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Step 7

Insert stripped end of main cable into battery cable repair splice, tighten locking hex screw with hex wrench and slide insulator sheath over splice connection. Repeat if there's an additional main cable.

 

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Step 8

Reconnect battery cables to battery in reverse sequence of steps 2 and 3, connecting the battery cable wired to starter or solenoid first and the ground cable last. Properly position and tighten terminals on battery posts.

NOTE: The positive cable may have a fusible link auxiliary lead. If it is burned out, it must be replaced in addition to installing the new cable.

 

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Download

 

Still have questions? Give our Technical Support a call at 1.800.654.4757.

Topics: How To, Automotive, Industrial, Truck/Trailer, Specialty Vehicles, Agricultural

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