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Thread: Replacing Td5 Battery/Chassis/Engine Earth Cable

  1. #1
    Join Date
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    Replacing Td5 Battery/Chassis/Engine Earth Cable

    I am getting close to firing up the Td5 Defender after a long rest while I installed a home-made Ebox and H/Duty cables for a winch. The original 40mm2 battery/chassis/engine earth cable was partly rubbed through so decided to replace and uprate.
    Td5 Original Battery-Chassis-Engine Earth Cable.JPG
    Battery to chassis earth point is now 70mm2 cable, chassis to transfer case is now 50mm2 cable and I have also connected the 50mm2 winch negative to the chassis earth point. All cables have double crimped copper lugs and are stacked onto the original chassis M8 earth point bolt with dielectric grease.
    Td5 Modified Battery-Chassis-Engine Earth Cable.JPG
    Td5 Modified Chassis Earth Connection.JPG
    I am a little concern though that the stacked lugs are not as good a connection as the original continuous earth cable with mid-cable lug.

    Td5 Original Chassis Earth Connection.JPG
    Has anyone else stacked lugs on the earth point with a discontinuous engine earth cable or does this cause problems?
    Martin

    The secret to happiness is to truly want what you already have
    Oil leak?...Nah, sophisticated anti corrosion system!


    '04 D2a TD5 Manual "Snowy" - Daily
    '04 Def 90 TD5 "Hue" - New toy
    '03 Def 90 TD5 - Son's toy
    '16.5 D4 TDV6 - Gone




  2. #2
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    Did the same, working just fine.

  3. #3
    Join Date
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    The "middle cable lug" that you speak of is a really poor connector on these vehicles.

    Most of the ones I've had anything to do with are failing or failed, the crimp loses tension, corrosion sets in, and then you get to use your handbrake cable as the earth strap.

    What you have done is exponentially better.

  4. #4
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    Thanks Tombie and Shack for the confirmation, good to hear. I did try making a mid-cable P-clip out of 3mm copper and soldering but couldn’t get the solder to seal all around the P-clip. It did wick down the cable about 3 cm each side though, creating a nice hard spot waiting to fail. Much happier with the lugs.
    Martin

    The secret to happiness is to truly want what you already have
    Oil leak?...Nah, sophisticated anti corrosion system!


    '04 D2a TD5 Manual "Snowy" - Daily
    '04 Def 90 TD5 "Hue" - New toy
    '03 Def 90 TD5 - Son's toy
    '16.5 D4 TDV6 - Gone




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