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Battery gauge

Transit Mk3, 4 & 5(smiley front) Forum. All Transits 1986 - 2000

Battery gauge

Postby twin wheel camper » Wed Apr 19, 2017 6:22 pm

What is the original correct battery gauge on a mk5 from Battery to starter in mm2 from new ??
I know you can't go to big but my pressure washer driven by a 2.5di is heating the battery cable up when starting and a few morning ago failed to start until I put the jump leads direct to the starter from the battery so it's time to replace the cable.
so what is the minimum gauge cable needed would 16mm get me away or should I get 25 mm ??
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Re: Battery gauge

Postby robbie.cee » Wed Apr 19, 2017 7:12 pm

Check the earth first. Shit earth will make more resistance which pulls more current hence hot cables....

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Re: Battery gauge

Postby robbie.cee » Wed Apr 19, 2017 7:13 pm

May need to sand paper or wire brush connectors etc

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Re: Battery gauge

Postby twin wheel camper » Wed Apr 19, 2017 7:24 pm

Thanks for the reply robbie the connections are ok I've cleaned then before.
The earth isn't good either it's smoking aswell :lol:
But putting the jump lead from the earth on the gearbox to the earth on battery still It won't start but when I done same to the positive cable she turned a bit faster and fired up so I'll be changing both ASAP
I just need to no the correct cable size
This morning it started no problem :x it must be a female engine :lol: one day all ok then for no reason all up the left!!
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Re: Battery gauge

Postby robbie.cee » Wed Apr 19, 2017 8:38 pm

100amp cable dunno the swg or awg but go to city electrical factors and ask for some 100 or 200 amp meter tails cost you bout 10 quid for a meter of each colour.

Solder the fittings on if you can too

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Re: Battery gauge

Postby robbie.cee » Wed Apr 19, 2017 8:40 pm

Put wires in bucket of water with tips out use plumbing torch and flux (shed load) and solder the fittings on good and proper.. a pony bnq blowlamp prob wont get hot enough so a map gas or rothenberger type will be ideal.

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Re: Battery gauge

Postby robbie.cee » Wed Apr 19, 2017 8:41 pm

And copper grease or vaseline over nuts etc once refitted

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Re: Battery gauge

Postby F111ORY » Wed Apr 19, 2017 9:57 pm

I don't know the answer but can tell you that Mk5 battery cables are thinner than Mk3 battery cables. When mine failed I replaced them with 40mm cable. She starts like a good un now.

People will often spend a fortune on starters and batteries when all they needed was new cables!
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Re: Battery gauge

Postby vanfox » Thu Apr 20, 2017 9:43 am

Visit the breakers and take your pick, simples.
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Re: Battery gauge

Postby Mfr » Thu Apr 20, 2017 3:01 pm

robbie.cee wrote:Put wires in bucket of water with tips out use plumbing torch and flux (shed load) and solder the fittings on good and proper.. a pony bnq blowlamp prob wont get hot enough so a map gas or rothenberger type will be ideal.

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I used plumber's flux when doing mine but I am finding that over time the copper is leaching green dust because the plumbers flux is too aggressive on thin strand cable (acidic). I Just use the solder on its own or use electrical liquid flux, just got some yesterday, works well.

I would not go below 25mm squared on the starter cable. I used 40mm and 35mm when I renewed all mine.

https://www.fordtransit.org/forum/viewt ... 7&start=15
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Re: Battery gauge

Postby Aardvark » Thu Apr 20, 2017 6:11 pm

I have had hard starting for years, and total refusal to start about two weeks ago so I replaced every cable and cleaned every connection remotely related to the starting system. My main cables were showing a lot of corrosion where they enter the terminals. No real mystery there because whenever it rains the whole battery area gets wet! I decided to bite the bullet and go with my marine electrics experience. I used 25mm sq. tinned copper cable to replace the pos and neg from the battery. I have a massive crimper and had planned on soldering as well but I tried to start it after they were crimped on and WOW! It starts before I even hear it turn. It's like instant. The tinned copper stuff was pricey http://www.12voltplanet.co.uk/extra-flexible-tinned-copper-pvc-batterywelding-cable-25mm-170a.html but it will refuse to corrode like bare copper. If it works in the salt laden atmosphere at sea it should survive in a Transit.
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Re: Battery gauge

Postby DodgeRover » Thu Apr 20, 2017 7:47 pm

I used 70mm sq welding cable and twin batteries on my pinto, it spins over nicely :)
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Re: Battery gauge

Postby F111ORY » Thu Apr 20, 2017 8:00 pm

I made this video ( at Christmas) for a tractor forum.

https://www.youtube.com/watch?v=jsD6RSs5_4U
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Re: Battery gauge

Postby Mfr » Fri Apr 21, 2017 12:35 pm

Love the intro to the Vid! Wow tinned cable, you can't get better than that. :D
A few years back my dad had a little Citroen C2 and it wouldn't start without a jump, he called out the AA who sold him an £90 battery :evil: :evil: I had some left over cable for the van so I did the C. Started first time every time after that. I think the AA got hauled over the coals about that. I just wish I had been there at the time :evil:
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Re: Battery gauge

Postby jonochap » Sat Apr 22, 2017 9:53 am

Great watch and nicely done, very tempted to try that now


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