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I'd like to give a shout out to TXDoug, his thread got me moving on this project.
Phase 1: secure the battery connections and update the terminals.
All of the main components were purchased from Amazon. I started with the crimp tool, it works great and has a variety of Dies that supported 4 awg to 4/0 awg.
All the shrink wrap is Ancor marine grade. I purchased 1" and 3/4". The 1" was great for 1/0 - 4/0 while the 3/4" was great for 4awg up to 2/0. I got both Red and Black to help with cable identification. A Black and Decker heat gun worked to shrink and active the adhesive.
I started with some corroded cables on both the Passenger and Drivers side. I had some audio cables that needed to be replaced too.
This started by removing the terminal connections, the batteries and the battery trays. The battery is secured with an 8mm bolt, the battery trays are secured with 4 13mm bolts.
It only took 30 minutes to get this far, however, making that first cut took an hour. Once you make that cut, there is not turning back. I got the cable cutters from Harbor Freight for $6.99 and used a 25% off coupon.
With the cables cut, I cleaned them using Vinegar and then a water/baking soda solution to naturalize the acid. This cleaned the cable nicely and prepared them for the new terminal ends.
With the ends prepared, I started the process of crimping new lugs. I added dialectic grease to the terminal and inserted the prepared bare cable. I completed 2 crimps 90* to each other.
When all the crimps were completed, I reinstalled the freshly cleaned and painted battery trays and then the batteries. I'm very pleased with the finished product.
After connecting everything up, I fired up the truck and it roared to life. The starter turned over faster and from the drivers seat, it appeared to fire quicker. I'm seeing 14.18 at idle with my stock 110 amp alternator.
There are two pics of the ends that were removed from the passenger and drivers side.
Phase 2: Update the alternator to a Bosch 140 amp from a 6.0.
Phase 3: Add additional grounds from the Alternator mount and charge cable to the passenger battery. I have a fuse to protect the additional charge cable.
I'm happy this is done and the connections are easier to service in the future. I know they are all sealed from both air and water. I look forward to this being secure for years to come.
Jesser02EX, reps sent for the time and effort taken for the write up!
I have a few questions though if you have a moment.
1. What size and type of fuse and gauge of wire did you use for the additional + wire from the alternator to the passenger side battery?
2. What gauge wire did you use for additional - wire to the passenger side battery?
3. Do you have any pictures of the alternator with the additional wires you could post up?
4. Why run the additional wires to the passenger side instead of the drivers side which is closer? Is this because the passenger side is the last battery in the line before the starter?
Reps sent, and on account of your story here I ordered me up a supply of 1/2", 3/8" and 1/4" marine grade heat shrink with adhesive for stock, all in black, made in USA.
What did you use on the wire looms ends? Same heat shrink or something else?
The primary shrink wrap is Ancor because I believe it's better. I also got cheap Harbor Freight Marine shrink wrap for less critical areas. Finally, I wrapped the ends with either red or black electrical tape.
Jesser02EX, reps sent for the time and effort taken for the write up!
I have a few questions though if you have a moment.
1. What size and type of fuse and gauge of wire did you use for the additional + wire from the alternator to the passenger side battery?
2. What gauge wire did you use for additional - wire to the passenger side battery?
3. Do you have any pictures of the alternator with the additional wires you could post up?
4. Why run the additional wires to the passenger side instead of the drivers side which is closer? Is this because the passenger side is the last battery in the line before the starter?
I'll complete Phase 2 and 3 over the coming weekend.
You caught my mistake, the extra ground will connect to the Drivers side battery.
The charge wire will to the new alternator using 2 AWG wire. The Ground from the alternator mount to the drivers battery will be 2/0.
The extra charge wire will connect to the drivers battery via a
