New to the group, but have been lurking and enjoying the numerous issues
that have been dealt with. I picked up a '97 2dr Tahoe a while back for a
song and have been spending the last few months taking care of neglected
maintenance issues,as well as making my own modifications. I'm working on
the electrical problems and have run into something I'm not sure how to
handle. I'd just replaced the positive battery cable and began to focus on
the positive relay cable that comes off the side terminal and runs across
the fan shroud and into the fuse relay box. The joker that had the truck
before me attempted to crimp a 12-16 awg terminal ring onto what must be a
6-8 gauge wire at the battery post end. This seems to be at least one
source of much of my electrical frustrations. None of the parts stores
locally carry this relay cable or the correct sized terminal rings to make a
proper connection (NAPA tech even told me he had tried securing these from
GM for quite some time to no avail). Are there any sources from where I
could order the replacement, and could I, in the meantime, run your typical
size 4 awg positive cable in its stead? What concerns are there in doing
this? Where could I ground the cable? Appreciate anything you can offer
any electrical supply house that suppies electricians will have a tern=minal
of that size
or a welding supplies place
you may need to take the cable entirely off and crimp it in a vise, to get a
good crimp; then heat it and flow solder into the joint, followed by a
couple layers of shrink-tubing to get a weather-tight joint
Done! Got it all hooked up with the proper connections. Found a terminal
that would work with the application at the local electrical supply and took
it from there. Thanks for the info.
- Gary sorry for that direct email, hit the wrong reply button.
This cable is a ~$55 dealer item, I have looked myself.
There was some past discussion on the failure of the lead spacer of the double
lug on the battery
post. It would cause a bad connection and pose a 'Load dumping' situation on the
Since the GM alternator uses Avalanche diodes, it usually fails.
Find out more here >> http://subtopics.freeyellow.com/Batteries-Charging.htm
As Gary pointed out, you can crimp or solder flow a lug to the cable you
mentioned. and connect it
to the battery. If you replace the cable, replace it with the same size
Wasn't there some problem with the bolt on the battery terminal being too
long and breaking the connection loose internal to the battery? I seem to
remember reading on here about that.
Also if you do solder the connector, be carefull , I soldered the battery
connection on our Plemon and the connector itsself started to melt, I
believe they are made of lead which is partly what solder it made of, guess
I got it a bit too hot.
Yeah, I had a '98 Chev 1/2 p/u and I installed a second battery. I made all
of the wiring harnesses myself using 1/0 arc welding cable and some ends
from Princess auto. Also, since some car audio nuts sometimes go nuts
installing bigger batteries and the such in their vehicles, I found a lot of
those places also carried battery connections, but they can sometimes be a
little costly, but the quality is great.
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