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Suggestions and Recommendations for 'hardening' your Vehicle's Electrical System Electrical failures are one of the most common breakdown's on offroad vehicles. Poorly mounted batteries and loose & corroded connections will ruin your offroad experience. Most electrical failures can be prevented without expending a lot dollars. |
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Symbol for Degree of Necessity * - splurge a little ! ** - if you can afford it *** - nice to have or do **** - should have or do ***** - must have or do ! - good to upgrade at replacement !! - should be upgraded at replacement |
Code for Vehicle Rating 1 - essentially bone stock: trails up to 2 2 - + larger than stock tires, tow hooks front and rear: trails up to 2.5 3 - + aggressive tires 31 inches and larger; one axle with traction-aid device: trails up to 3.5 4 - + Locking differential on one axle: trails up to 4 5 - + aggresive tires 32 inches and larger & both axles with locking differentials: trails up to 4+ |
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| Battery(s) | ***** Use
positive-style bolt-down battery hold-downs. no bungie or rubber cords ! *** ! Suggest using spiral-cell type batteries (i.e. Optima®, Orbit®, etc.) - these batteries can be operated & mounted in any position without acid spillage, these batteries have stronger cases and usually are higher rated as to output and capacity. Most have 7 year warranty. ** Suggest Dual Batteries - especially when vehicle is equipped with a winch - battery isolator |
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| Battery Cables | Use Ready-made 2 gauge
cables as the minimum.
Suggest making them from #2 or larger welding cable - welding cable has a 'high-strand count' which makes them more flexible, carry more current (especially in cold weather) & the insulation is specifically made to be highly abrasion and temperature resistant when calculating & cutting the cables to length (especially on the battery (-) or ground to engine length) - be sure to allow for engine movement in the mounts. If you have any doubts as to how much to allow, use the original cables and add a few inches of extra length.strip insulation & solder eye-style ends use the best marine grade/brass/gold-plated battery connectors that you can affordshrink tube or sleeve the last few inches of battery cable before the battery - acts as strain-relief wherever there is any chance of cables rubbing - put some kind of sleeving on the cable to prevent chaffingif you try to seal the connections - DO NOT USE RTV/SILICON-type sealants - there is acetic acid in RTV which will promote corrosion of connectors and connections - use GOOP® or other rubber or latex-based sealers - (This applies to all electrical components) |
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| Electrical connections | if you try to seal
the connections DO NOT USE RTV/SILICON Sealers - there is acetic acid in RTV which will promote corrosion of connectors and connections - use GOOP® or other rubber-based sealers |
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| upgrade alternator & alternator wiring | |||