Battery cable gauge

Flivver250

TJ Addict
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Does anyone know the gauge of wire on the battery cables? I am guessing it is about 2, but guesses start fires. I want to get some inventory of cable and terminal clamps for general maintenance use. My clamps are a bit beat on so it would not hurt to start fresh and have left over product for the next project.
 
If i remember my electronic school correctly. Been a few years. As long as the positive and negative are the same gauge you can go thicker without risking an overload.

2 gauge seems popular

The way it was explained to me was. If you have a 2 inch supply hose you need a 2 inch return. It will only take the power it needs.
 
Does anyone know the gauge of wire on the battery cables? I am guessing it is about 2, but guesses start fires. I want to get some inventory of cable and terminal clamps for general maintenance use. My clamps are a bit beat on so it would not hurt to start fresh and have left over product for the next project.

I found this site a while back and saved to favorites for a future project. Even if you don't buy their cables, there's a lot of good pictures and gauge reference information.

https://www.custombatterycables.com/jeep-wrangler/
 
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4ga is ample given the short runs on a TJ. I prefer the military-style clamps and heat-shrink sealed ring terminals for the all the runs. I ran an extra ground to the firewall and ground stud on the engine. Wire is cheap and add a little split-loom for protection on the positive feed.

If you add a winch, heavier gauge cable may be needed.
 
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I put dual batteries in my TJ and I replaced all of my main cables with 2gauge the factory was 4. Then I replaced my cables on my Aux battery with 1 gauge, but then I bought a winch and used the two gauge wire that came with the winch. When they go bad I will probably replace them with 1 gauge, but honestly your 4 gauge would be sufficient for normal needs, but it isn't going to hurt to upgrade to 2 by any means. It was fairly easy to do also. As someone previously mentioned, I used military terminals.
 
Mine seemed like #6, tiny.

Before putting on my winch I redid my starter, alternator, main fuse link, frame ground, and motor ground all with #2 wire with ends crimped and soldered. I only use pre-tinned marine finely stranded cables. After rewiring the power systems in my boat I really like the cable so now I use it on everything. Being pre-tinned really helps with corrosion as well. My buddies and I do lots of big boat battery systems and #2 is the minimum gauge cable we use. Length is a big factor as well, if you add a load or source that requires more than 10' of cable I would step up a gauge so you don't lose any voltage. With 20' between the batteries and the loads on my boat I use 1/0 cable. Its way overkill from a ampacity standpoint but it is helpful to maintain those critical 0.1 or 0.2 volts that would otherwise be lost.

When it comes to something like winching you can easily and quickly overload the factory wiring systems. Sure they work fine when they only need to supply high current for a couple seconds to the starter but winching is a completely different load. One other benefit is bring able to start in gear or use your starter motor to move the Jeep a short distance. The heavier cable will supply more voltage under load as well as avoid overheating.
 
Does anyone know the gauge of wire on the battery cables? I am guessing it is about 2, but guesses start fires. I want to get some inventory of cable and terminal clamps for general maintenance use. My clamps are a bit beat on so it would not hurt to start fresh and have left over product for the next project.

Hi @Flivver250 ,
The TJ OEM batery cables are 4 AWG.
 
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Im almost certain we (motor pool, ground support equipment) get stuff like that from a civilian store. At one point all we used was red top optima batteries. They were the best (at one time). now im not sure what we are running. But the clamps were just off the shelf clamps. Nothing special.
 
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Im almost certain we (motor pool, ground support equipment) get stuff like that from a civilian store. At one point all we used was red top optima batteries. They were the best (at one time). now im not sure what we are running. But the clamps were just off the shelf clamps. Nothing special.

For now, I just used ones I posted earlier. If you have a better option, I am always willing to upgrade when possible.
 
For now, I just used ones I posted earlier. If you have a better option, I am always willing to upgrade when possible.
The ones posted are good. I just hate companys claiming military style, grade, spec, the military buys shit from the lowest bidder. Get parts from the cheapest way.
Also over the past 40 years have shifted to an off the shelf system. When you are in the middle of nowhere you can get anything you need form anywhere.
 
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The 'military style' term was from way back and the fact that the terminal clamps are separated from the cables.. I have a set from Custom Battery Cables on my Jeep and love them. Much beefier than what I had on. I thought I ordered the military style clamps but goofed and didn't. I wanted them for the ease of attaching accessories to the terminals easier - winch, offroad lights, etc. All I did was get a longer terminal clamp bolt from the hardware store and some extra nuts.. works like I wanted.