1996 XJ Battery Cable Gauges?
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Joined: Aug 2019
Posts: 1,601
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From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
https://www.batterycablesusa.com/2-g...ry-cable-black
665 strands sounds real good, but not sure how good it is. The strands in my stock cable look pretty thin, so I know there are a lot of them in there. And it looks like a lot more strands than parts store off the shelf cable too.
665 strand in a 2-gauge wire is what you'd find in welding cable where you need a lot of flexibility and resistance to fatigue from constant movement. Do you need that much flexibility for underhood battery cables? Probably not, but it does make it much easier to route and tie down. If the price difference isn't much, it's worth it. That looks like it has a nice oil/grease resistant jacket too.
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CF Veteran




Joined: Aug 2019
Posts: 1,601
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From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
665 strand in a 2-gauge wire is what you'd find in welding cable where you need a lot of flexibility and resistance to fatigue from constant movement. Do you need that much flexibility for underhood battery cables? Probably not, but it does make it much easier to route and tie down. If the price difference isn't much, it's worth it. That looks like it has a nice oil/grease resistant jacket too.
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Joined: May 2012
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From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
At any rate, you want the big hot lead and the big ground lead to be the same size.
665 strand in a 2-gauge wire is what you'd find in welding cable where you need a lot of flexibility and resistance to fatigue from constant movement. Do you need that much flexibility for underhood battery cables? Probably not, but it does make it much easier to route and tie down.
Yep. That high-strand wire is a lot nicer to work.
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CF Veteran




Joined: Aug 2019
Posts: 1,601
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From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
CF Veteran




Joined: May 2012
Posts: 7,965
Likes: 964
From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
Oh, you have a 96! The weird year! I'll have to check mine to see what sizes it has.
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Joined: Aug 2019
Posts: 1,601
Likes: 226
From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
And this is the parts list I am going with from Del City Electronics to swap my battery terminals to Ordinance/Military and clean up the messy ends. Also using De-Ox-Id and see how it does on corroded copper (they don't have De-Ox-It at my electrical jobber).
Item Description Price Qty Total
901075 Lead Battery Terminal, Ordinance Bolt Type, Positive (1 MIN) $5.44 $5.44
901085 Lead Battery Terminal, Ordinance Bolt Type, Negative (1 MIN) $5.44 $5.44
916800 3/8" Copper Tin Plated Lug, 8 Ga (5 MIN) $0.80 $ 4.00
92920438 Compression Nut Heavy Wall Lug, 3/8" Stud, 4 ga (1 MIN) $7.15 $14.30
92920638 Compression Nut Heavy Wall Lug, 3/8" Stud, 6 ga (1 MIN) $7.15 $7.15
92922138 Compression Nut Heavy Wall Lug, 3/8" Stud, 1 & 2 ga (1 MIN) $7.14 $14.28
98084500 4 ft. Red 4:1 Adhesive Lined Heat Shrink, 3/4" (1 MIN) $9.66 $9.66
Item Description Price Qty Total
901075 Lead Battery Terminal, Ordinance Bolt Type, Positive (1 MIN) $5.44 $5.44
901085 Lead Battery Terminal, Ordinance Bolt Type, Negative (1 MIN) $5.44 $5.44
916800 3/8" Copper Tin Plated Lug, 8 Ga (5 MIN) $0.80 $ 4.00
92920438 Compression Nut Heavy Wall Lug, 3/8" Stud, 4 ga (1 MIN) $7.15 $14.30
92920638 Compression Nut Heavy Wall Lug, 3/8" Stud, 6 ga (1 MIN) $7.15 $7.15
92922138 Compression Nut Heavy Wall Lug, 3/8" Stud, 1 & 2 ga (1 MIN) $7.14 $14.28
98084500 4 ft. Red 4:1 Adhesive Lined Heat Shrink, 3/4" (1 MIN) $9.66 $9.66
BTW, De-Ox-Id (vs DeoxIt) does not appear to do anything different than rubbing alcohol. No instructions on the bottle, nor anywhere online. According to my local big electronics place where I bought it, the stuff is supposed to remove oxidization like DeoxIt. Not from what I see. Don't waste your money on this stuff.
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Joined: May 2012
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Likes: 964
From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
Just use a brass brush and follow up with dielectric grease.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
Thread Starter
CF Veteran




Joined: Aug 2019
Posts: 1,601
Likes: 226
From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
Just use a brass brush and follow up with dielectric grease.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
Last edited by 318SixPack; Nov 17, 2019 at 08:01 PM.
Senior Member





Joined: Oct 2019
Posts: 789
Likes: 233
From: Current XJ is
Year: 95
Model: Cherokee (XJ)
Engine: 4.0
Just use a brass brush and follow up with dielectric grease.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
BTW, here's a list that should give you the lengths you need for the cables. I have no idea if this guy is still in business. A lot of people here were very happy customers, but he's been pretty quiet for a while.
http://www.geocities.ws/jeepi6power/price.html
Cruiser54 has been recommending MeanLemons.
Thread Starter
CF Veteran




Joined: Aug 2019
Posts: 1,601
Likes: 226
From: East Tennessee
Year: 1996
Model: Cherokee (XJ)
Engine: 242 cui
A place with a lot more variety, if I decide to go with marine grade cable later, is these guys.
http://www.bestboatwire.com/
They even have adhesive lined green shrink tube for that little wire that goes to the starter. 2 and 4 AWG tinned cable is slightly better price than Battery Cables USA. Even their military style battery terminals are less than everybody else.
Not sure how that all holds up at final checkout. Going to be a while before I change battery cables anyway.
http://www.bestboatwire.com/
They even have adhesive lined green shrink tube for that little wire that goes to the starter. 2 and 4 AWG tinned cable is slightly better price than Battery Cables USA. Even their military style battery terminals are less than everybody else.
Not sure how that all holds up at final checkout. Going to be a while before I change battery cables anyway.
CF Veteran




Joined: May 2012
Posts: 7,965
Likes: 964
From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
Yes, I am QUITE sure I don't mean conductive grease. Independent tests show that there is no such thing, despite what you may have read, or the manufacturer claims. In fact, it has exactly the same resistivity as dielectric grease.
EXACTLY THE SAME.
No-Ox and it's competitors are made for ALUMINUM POWER connections, NOT for automotive use. The zinc content is intended to reduce corrosion in ALUMINUM POWER CONNECTIONS by acting as a sacrificial metal. It's not intended for copper connections.
https://www.cherokeeforum.com/f2/die...0/#post3575409
http://www.w8ji.com/dielectric_greas...ive_grease.htm
https://www.cherokeeforum.com/f2/fus...9/#post3492129
https://www.cherokeeforum.com/f2/ele...0/#post3279926
A place with a lot more variety, if I decide to go with marine grade cable later, is these guys.
http://www.bestboatwire.com/
http://www.bestboatwire.com/
Senior Member





Joined: Oct 2019
Posts: 789
Likes: 233
From: Current XJ is
Year: 95
Model: Cherokee (XJ)
Engine: 4.0
Yes, I am QUITE sure I don't mean conductive grease. Independent tests show that there is no such thing, despite what you may have read, or the manufacturer claims. In fact, it has exactly the same resistivity as dielectric grease.
EXACTLY THE SAME.
No-Ox and it's competitors are made for ALUMINUM POWER connections, NOT for automotive use. The zinc content is intended to reduce corrosion in ALUMINUM POWER CONNECTIONS by acting as a sacrificial metal. It's not intended for copper connections.
https://www.cherokeeforum.com/f2/die...0/#post3575409
http://www.w8ji.com/dielectric_greas...ive_grease.htm
https://www.cherokeeforum.com/f2/fus...9/#post3492129
https://www.cherokeeforum.com/f2/ele...0/#post3279926
I have used them about half a dozen times, between a few vehicles. I recommend them regularly. The quality is excellent and the prices are good. I like to specify the clear heat shrink so I can keep an eye on the connections. Hidden corrosion is the worst corrosion.
EXACTLY THE SAME.
No-Ox and it's competitors are made for ALUMINUM POWER connections, NOT for automotive use. The zinc content is intended to reduce corrosion in ALUMINUM POWER CONNECTIONS by acting as a sacrificial metal. It's not intended for copper connections.
https://www.cherokeeforum.com/f2/die...0/#post3575409
http://www.w8ji.com/dielectric_greas...ive_grease.htm
https://www.cherokeeforum.com/f2/fus...9/#post3492129
https://www.cherokeeforum.com/f2/ele...0/#post3279926
I have used them about half a dozen times, between a few vehicles. I recommend them regularly. The quality is excellent and the prices are good. I like to specify the clear heat shrink so I can keep an eye on the connections. Hidden corrosion is the worst corrosion.
There's no zinc,no sacrficials etc. in No- Ox ID A Special. And it is for copper. It's recommended to NOT use it on multi pin connections. Here's some interesting reading from
guys dealing with environments far worse than what I deal with day in day out in the Pacific Northwest
https://www.practical-sailor.com/iss...e_11969-1.html
https://www.practical-sailor.com/iss...ns_5938-1.html
https://www.practical-sailor.com/iss...st_5989-1.html
At the end of the trail some greases are better than others on electrical connections and any grease is better than none at all.
Last edited by ijeeep; Nov 19, 2019 at 10:04 PM.
CF Veteran




Joined: May 2012
Posts: 7,965
Likes: 964
From: Lost in the wilds of Virginia
Year: 1998 Classic (I'll get it running soon....) and 02 Grand
Model: Cherokee (XJ)
Engine: 4.0
Despite the manufacturer's claims, independent tests say it's not conductive. Read the MSDS. It's petrolatum (Vaseline) with some chemicals in it.
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