I recently had the starter (positive) terminal connector on my 2002 F150 (4.6, 4x4) corrode to a point of snapping. I decided to try the cheap route and bought a new copper terminal connector at the local Auto Zone for a few bucks and cut the end off of the cable, put on the new terminal connector, crimped it best I could with the pliers I had on hand. My crimpers were for much smaller wire and wouldnt work. I feel the crimping could have been better with a better tool. I cleaned up the post with some sandpaper lightly, just enough to get any corrosion or debris off. I then used electrical tape to seal it. The heat wrap at the auto zone wasn't big enough to cover this gauge wire. I would be willing to get some online or elsewhere. Truck now starts up.

Question is: is this a short term fix? Will the job I did work well enough without causing fire/explosions/electrical issues etc ? I am not mechanically inclined, the tools I have are mostly for wood working and I only have knowledge of electrical processes and fixes from my dad who taught me how to wire and rewire electronics when I was many years younger than I am now! I felt like I did well enough but now I am having second thoughts and don't want to run into problems while out driving or have something go awry next time I start it up. I am not sure of the quality of the terminal connectors from auto zone but they seem rather universal in design and quality to any others I have seen.

I appreciate your feedback in advance.

Dominic

 

had the same thing happen to my 01 last summer so I guess we know the life expectancy of that terminal

did the same fix on the cheep with what I had on hand at home - still working today

with a 17-18 year old truck the best thing to do is buy a membership with AAA or CAA (dono your location) for the free towing
buy the free towing package that best fits your needs / uses

I got lucky with no current CAA membership last summer
sitting in the lot for about an hour with my dog in the truck to boot along came one of CAA's tow trucks which parked right beside me
60 bucks got me home

 

A down and dirty Crimper can be fabricated by sawing a square nut of about 3/8 diameter thread and squeezing it around your terminal in a vise. Ain't pretty, but makes for a serviceable crimp.

 

Good, that sounds like it might be good enough to keep me going for a while. I will still try to get some heat wrap for it because I do not have a ton of faith in electrical tape.

 

Awesome idea, I had considered a using vice grips or a clamp, this is a good idea though. Thanks! Will give it a whirl.

 

I had the same problem, bought the same lug end...... but I used a propane torch and soldered the lug to the original wire... then wrapped with electric tape.

 

most auto parts stores sell "Liquid Tape", that you can paint onto the wire ends and it dries into rubber... like a very thick paint... that is an option...... and if you want a better CRIMP. squeeze it with a small set of vice grips.