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Corroded Battery Cable Replacement (tons of pics/summary)
I had Napa brand "battery" cable for my winch, but after getting 5-90's made in US welding cable I could tell an immediate difference, for the better. I spent a lot of money on these cables, and would do it again over store bought.
Also I notice a lot of you are against those basic crimpers, but if you have a strong grip there's really no small terminal they can't crimp. I use the exact one pictured above that a few of you have said stay away from, and never once had an issue with a crimp. I use 3m terminals, ones where the metal to be crimped has a small angle so when crimped it curls downward, solid crimp every time. I don't doubt the other style of crumpet is better, but having used the "bad" one for 5 years no with no problem, I don't see the need to run out and get a special one.
Senior Member
Joined: Jun 2014
Posts: 925
Likes: 6
From: Eagle River, Alaska
Year: 1999
Model: Cherokee (XJ)
Also I notice a lot of you are against those basic crimpers, but if you have a strong grip there's really no small terminal they can't crimp. I use the exact one pictured above that a few of you have said stay away from, and never once had an issue with a crimp. I use 3m terminals, ones where the metal to be crimped has a small angle so when crimped it curls downward, solid crimp every time. I don't doubt the other style of crumpet is better, but having used the "bad" one for 5 years no with no problem, I don't see the need to run out and get a special one.
Agreed. Its worked for everything I've needed it to as well.
CF Veteran
Joined: Oct 2013
Posts: 5,924
Likes: 203
From: Greenville, SC
Year: 1999
Model: Cherokee(XJ)
Engine: 4.0
CF Veteran
Joined: Oct 2013
Posts: 5,924
Likes: 203
From: Greenville, SC
Year: 1999
Model: Cherokee(XJ)
Engine: 4.0
$130 for his set. I don't know if that's before or after shipping though
Senior Member
Joined: Jun 2014
Posts: 925
Likes: 6
From: Eagle River, Alaska
Year: 1999
Model: Cherokee (XJ)
Thats them building the cables to my specs, end links heat wrapped, brass marine terminals. 5-90's 4awg for the five cables is $60 according to his website, but that doesn't include terminals, shipping and the wait I couldn't afford at the time. Its a comparable price and I would have rather given him the business, but I needed them immediately.
CF Veteran
Joined: Oct 2013
Posts: 5,924
Likes: 203
From: Greenville, SC
Year: 1999
Model: Cherokee(XJ)
Engine: 4.0
Thats them building the cables to my specs, end links heat wrapped, brass marine terminals. 5-90's 4awg for the five cables is $60 according to his website, but that doesn't include terminals, shipping and the wait I couldn't afford at the time. Its a comparable price and I would have rather given him the business, but I needed them immediately.
All his kits have ends. He doesn't make you crimp your own haha. His $60 kit is just the basic mains: 4awg US welding cable, cut, crimped, heat shrunk.
For $80 you get the same kit but with the 36" cable that goes from alternator to pdc.
For $130 you get all the above plus a fuse holder and 2 ANL fuses.
These prices and lengths are for 4 awg for 97-01 XJ's, you'd have refer to his page to find out pricing for other years.
Also having handled both welding cable and dedicated battery cable, no question that welding cable is easier to route. I relocated my winch solenoid pack to the engine bay, and originally had 4awg Napa battery cable. Was hard to work with, didn't take bends to nicely, and just a pain to route where I wanted it. 5-90's 1awg welding cable however, or really any welding cable, is so much more flexible it's crazy.
For $80 you get the same kit but with the 36" cable that goes from alternator to pdc.
For $130 you get all the above plus a fuse holder and 2 ANL fuses.
These prices and lengths are for 4 awg for 97-01 XJ's, you'd have refer to his page to find out pricing for other years.
Also having handled both welding cable and dedicated battery cable, no question that welding cable is easier to route. I relocated my winch solenoid pack to the engine bay, and originally had 4awg Napa battery cable. Was hard to work with, didn't take bends to nicely, and just a pain to route where I wanted it. 5-90's 1awg welding cable however, or really any welding cable, is so much more flexible it's crazy.
CF Veteran
Joined: Aug 2010
Posts: 8,357
Likes: 103
From: Canton, MI
Year: 1999
Model: Cherokee
Engine: 4.0
Could someone school me as to why I should use AWG 4 cables instead of the OEM AWG 6 and AWG 8 cables.
And why use AWG 4 cable from the firewall to the #14 cylinder head bolt instead of the OEM braided strap.
And why use AWG 4 cable from the firewall to the #14 cylinder head bolt instead of the OEM braided strap.
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
Because bigger is better! Always! Right?
Right.
Hey, if your cables aren't bigger, what are you going to brag about?
But seriously, factories use cables that are adequate for their job, but not one bit bigger. Another way to say that is barely adequate.
If I need to replace my cables, I'll probably upgrade them a bit. 5-90s cables and ends are better quality than OEM, and will carry more current and last longer than OEM. They are also a sensible upgrade, unlike the idiots that use 00 welding cable.
That nonsense is a pure waste of money.
Right.
Hey, if your cables aren't bigger, what are you going to brag about?
But seriously, factories use cables that are adequate for their job, but not one bit bigger. Another way to say that is barely adequate.
If I need to replace my cables, I'll probably upgrade them a bit. 5-90s cables and ends are better quality than OEM, and will carry more current and last longer than OEM. They are also a sensible upgrade, unlike the idiots that use 00 welding cable.
That nonsense is a pure waste of money.




