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Battery cable woes!

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Old Nov 18, 2019 | 07:31 PM
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Battery cable woes!

So, even though I already got new battery cables the jabronis that made them apparently didn't know what they were doing. This is the second time these battery cables have failed. Check it out!



This evening I took my youngest daughter to the park. It was 70* and beautiful. Perfect weather to cruise in my truck.

When we left the park I started the truck. When I turned on the head lights all the electrical power went dead and the engine died.

I was able to crank the truck by using jumper cables to short the terminals of the starter relay. It never started. No 12V for the FSS I @$$ume.

I didn't want to wear out the starter and I knew momma's Festiva wouldn't be able to help my truck start with a jump. So, I called a tow truck.


While waiting for a tow I was able to pull the passenger's side + battery cable off of the terminal with little effort. The idiots that made these cables must have crimped them with Bob the Builder pliers. I am glad this didn't happen tomorrow at 0515 on my way to work. Plus, I know now not to use that electrical supply company to fabricate cables for my Oldsmobile. Updates to come.
 
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Old Nov 18, 2019 | 08:19 PM
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Improper Crimp is my guess, looks like the cable just pulled out of the Clamp.
That suxor
 
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Old Nov 18, 2019 | 08:20 PM
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Yikes! It seems even the simplest tasks given to fully certified people cannot be completed successfully anymore. It gets old having to do it all yourself but nobody else can be trusted lately. That sucks about having to wait on a tow truck, but at least it failed there and not in traffic somewhere, or caused a fire or something crazy. Hopefully there’s enough cable left to wrap around somebody’s neck... lol
 
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Old Nov 18, 2019 | 08:34 PM
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Originally Posted by 90Ford73
Yikes! It seems even the simplest tasks given to fully certified people cannot be completed successfully anymore. It gets old having to do it all yourself but nobody else can be trusted lately. That sucks about having to wait on a tow truck, but at least it failed there and not in traffic somewhere, or caused a fire or something crazy. Hopefully there’s enough cable left to wrap around somebody’s neck... lol
Yeah X2
Years ago I bought a Cheap Crimper https://www.ebay.com/itm/16-Ton-18-5...s/381994656066

it comes with a Replacement Seal Kit but after over 10 years of use I've never had an issue with it ... I do a lot of Marine Cable work so it has paid for itself many times.
I normally get my Cable ends from Interstate battery IF I need them in a Hurry, but cheaper to order them online if one can wait.
Altex Electronics is where I buy heatshrink.

BTW that crimper works great on Wire Rope too
 
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Old Nov 19, 2019 | 08:23 AM
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Same day-similar issue

Yesterday I had a similar issue as well. I replaced both batteries two weeks ago (with Motocraft batteries). Yesterday the vehicle started fine but after shutting off wouldn't crank or start. After checking the cables I found one end to basically be fubar-crimped by a monkey. I then made the great decision to just replace the end so I could get it back running....couldn't be that hard. Since this is the passenger side the end needs to be a bulky fella and after going to NAPA, o Reilly, and autozone I came up goose egg.

After further inspection that cable also looked like it may have a little internal corrosion. Since we just bought this about 6-7 months ago, and I've been going through it I think I'm going to just replace all the cables with local made or may make my own based on what I'm finding...

 
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Old Nov 19, 2019 | 11:32 AM
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I use a bit of Corrosion X on the cable before I make the crimp..... when you do a good Crimp it creates a Cold Weld .....the Corrosion X is probably not needed but it sure helps in the long term on large cables such as battery cables and those exposed to salt air as I have here.
Also IF you use a tool such as the one I posted, you will find clamping the tool in a Vise while using it is very helpful IF you don't have 4 hands.

here is a link that explains Crimps in a Nutshell ... https://hackaday.com/2017/02/09/good...d-connections/



 
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Old Nov 19, 2019 | 11:59 AM
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Originally Posted by Swaybar1
I think I'm going to just replace all the cables with local made or may make my own based on what I'm finding...
That's a bummer that you had similar problems. I am going to replace all my cables too. We'll see if I can get my money back for the custom cables I had made.

UPDATE on 10/21/23

I linked to this thread today and figured I would update this post in case anyone finds it in the future. No need to do TTT.

I ended up buying a set of cable crimpers from Amazon, they work great. I think Horrible Freight has the same kit.

Cable Crimpers Cable Crimpers


I also got military style battery terminals for my Bullnose truck and my 96 Oldsmobile. This definitely comes in handy when wiring an aftermarket fan (my Bullnose truck) and a ham radio (my 96 Oldsmobile).

Battery Terminals Battery Terminals
​​​​
 
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Old Nov 19, 2019 | 12:10 PM
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btw, the ignition battery cable...does anyone have a spec on that? I believe my current is 2 awg rope/or flex style welding cable but I wasn't sure if that was overkill since it appears very after market....😳
 
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Old Nov 19, 2019 | 12:40 PM
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Originally Posted by Swaybar1
btw, the ignition battery cable...does anyone have a spec on that? I believe my current is 2 awg rope/or flex style welding cable but I wasn't sure if that was overkill since it appears very after market....😳
I think the OEM may be closer to 4 or 6 AWG but I also use 2 AWG from battery positive over to the Relay.... 4 AWG is really Plenty for that wire.

EDIT: I just went out and looked and from the Other side of the Relay to the Starter solenoid I used 4 AWG
 
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Old Nov 19, 2019 | 10:26 PM
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My truck has what according to the po and looks the part, 99-03 powerstroke cables. Very happy with them. No clue who the vendor was.
 
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Old Nov 19, 2019 | 10:33 PM
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Originally Posted by DarkOverCast
My truck has what according to the po and looks the part, 99-03 powerstroke cables. Very happy with them. No clue who the vendor was.
I guess your Chinglish guy did a better job crimping.... the aftermarket cables have made money for me.... just saying....

They are not all bad.....
 
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