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I tried to start my truck today and found it had a dead battery. The positive cable would not come off easily. I ended up getting it off and but it looks like the battery cable got welded to the battery terminal? Anyone ever seen this before?
You need to make sure all your grounds are clean, and you might consider adding an extra one. I would replace the cables and make sure you use either QUALITY ones that have the wire moulded in the connection. Not your local chain auto parts store cheap ones. I used cheap ones from the chain parts house and had internal connection issues in the past with that design, and it took quite a while to find the issue. So it's either $ quality or the ones where you just clamp the wire. And then make sure all your wiring is in good condition under the hood. Nothing chaffed or burnt.
+2 on the poor connection between the post and clamp. Couple hundred amps drawn through a too small and somewhat crusty connection will create a surprising amount of heat and arcing. Clean it up with a wire brush or battery terminal cleaning tool and you should be good to go. Don’t worry if it left pitting, rotate the clamp so that the damaged areas don’t line up.
Routine checks of the clamp to post fit and cleanliness are a good idea. I’ve seen many batteries condemned when the real problem was poor charging and/or insufficient current to the starter due to a loose fit or corrosion.
You need to make sure all your grounds are clean, and you might consider adding an extra one. I would replace the cables and make sure you use either QUALITY ones that have the wire moulded in the connection. Not your local chain auto parts store cheap ones. I used cheap ones from the chain parts house and had internal connection issues in the past with that design, and it took quite a while to find the issue. So it's either $ quality or the ones where you just clamp the wire. And then make sure all your wiring is in good condition under the hood. Nothing chaffed or burnt.
Alternatively, you can opt for MlL style battery clamps just add a lug to the cable and you are good to go, it also makes it easy to replace clamps or add on wiring.
The MIL clamps are like $6 apiece. See below install of mil clamps in a Deisel E350
Try to avoid the above clamps at all costs. It is not a question of if they will fail, but when they will fail.
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