Wrangler 2004 TJ Battery Cables Replacement

WWII-Willys

WWII-Willys

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Hi Gang

I bought the replacement package from Jeep Cables Dot Com

The cables are excellent (well made) The problem is that there is no reasonable PDC 90 degree replacement connection/bracket/part which would connect the new cables properly without the EYELETS and heavy gauge wiring getting in the way for battery replacement time.

Anyone know of another company (or) method/technique to adapt the connectors at the point of the PDC connection?
Here's what you get in with their PACKAGE

OLD BRACKET

Thank You
 
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WWII-Willys said:
Hi Gang

I bought the replacement package from Jeep Cables Dot Com

The cables are excellent (well made) The problem is that there is no reasonable PDC 90 degree replacement connection/bracket/part which would connect the new cables properly without the EYELETS and heavy gauge wiring getting in the way for battery replacement time.

Anyone know of another company (or) method/technique to adapt the connectors at the point of the PDC connection?
Here's what you get in with their PACKAGE

OLD BRACKET

Thank You
Click to expand...

I have no personal experience with these, however, cutting the PDC plastic housing has been the solution many have used. Others who have actually done this may chime in.
 
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A little careful work with a utility blade will get you the clearance you need to attach the new cables.

PXL_20230711_124306014.jpg


inside fuse box.jpg


fuse box lid.jpg
 
Thanx for the pictures Mr. Lincoln

I've already researched what's neccessary ...

Don't you see where the heavy gauge wires are still in the way for a battery replacement (as I indicated)? This is an issue covered by several folks on You Tube. Its a problem that hasn't been addressed by Cables Dot Com. Others indicate the company actually marketed that package for a different Jeep (where the PDC cover is not at issue). I was looking for a possible new solution? A part or adapter? I guess there isn't anything out there?

I don't know if its possible, but I'll try to cut away the old wires from the old bracket and try to attach the new eyelets to the old bracket ....

Here's a You Tube channel (watch the re-direct) and see how this gentleman tried to manufacture a NEW bracket that would allow clearance for battery replacement.

Thanx
 
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I guess I misunderstood your question and thought you were asking about the PDC wire clearance from the fuse box. However, the wiring as I have it set up does not get in the way of removing or replacing the battery.
 
WWII-Willys said:
Don't you see where the heavy gauge wires are still in the way for a battery replacement (as I indicated)?
Click to expand...

Yes they are, or could be, in the way for battery replacement and could be designed better. However, how often are you changing out your battery? Looks like there will be an extra couple of nuts to be undone every few years or so. Similar to what happens with many of the upgrades and add ons we put on our TJ's, think skid plates and winches, that lead to extra steps when doing things. No offence intended but for me the added excellent quality of the cable set you purchased would far outweigh the inconvenience of removing the heavy gauge wires from the PDC at battery replacement time.
 
buildbigboats - GREAT job!

Mac67 - "an extra couple of nuts to be undone every few years or so"

I agree that's why I will settle for what I have(y)
 
buildbigboats said:
Agree with excellent quality of product. I like leaving things as original looking as possible so this is what I did... from a piece of copper plate

View attachment 440495
Click to expand...

That is a beautiful solution. Any concerns with leaving that positively charged slab of copper exposed like that? Seems eager to catch a stray wrench handle and arc to ground…or to the holder of said wrench 😬
 
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CharlesHS said:
Just wondering if you have a Fusible Link or a Buss Fuse installed in the PDC power cable ?
In the 1st picture there is a white plastic piece to the left of the power cables, but that may be a cable retaining clamp.
Click to expand...

Yes, that is a fuse that comes with the kit. I mounted it on the lower part of the air box.
 
Granite said:
"Seems eager to catch a stray wrench handle and arc to ground"
Click to expand...

Hello Mr. Granite!

GOOD POINT! Thus I have reached a SAFE and final decision, despite the fact the original design (although flawed), gave maximum convenience. That's the GREAT thing about having these discussions! MULTIPLE Well Formed Brains are better than one mediocre brain Ha! :ROFLMAO:

I will proceed with cover trimming and enjoy the improved protection of LIVE conductors (or as they say) 'Live Bus'

And as Jackie Gleason used to say "AWAY WE GO"!
jackie.jpg


Thank you EVERYONE
Great Bunch Of Guys!
 
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Granite said:
That is a beautiful solution. Any concerns with leaving that positively charged slab of copper exposed like that? Seems eager to catch a stray wrench handle and arc to ground…or to the holder of said wrench 😬
Click to expand...

Granite said:
That is a beautiful solution. Any concerns with leaving that positively charged slab of copper exposed like that? Seems eager to catch a stray wrench handle and arc to ground…or to the holder of said wrench 😬
Click to expand...

Once cover is back... everything buttoned up I'm not worried

PXL_20221209_210705514.jpg
 
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